Portable vacuum gripper

ABSTRACT

A vacuum gripper for gripping an object surface using vacuum suction is configured to be portable or operated by a hoist. Battery conservation measures are included to provide a long term vacuum generation capability, together with manually rechargeable mechanism. A manually-operated vacuum pump is also integrated to the vacuum gripper as a safeguard for the battery-operated vacuum pump failure. The vacuum gripper includes an elastic deformable vacuum seal for gripping objects with irregular surfaces, together with press rods or pin array configured to assist the vacuum seal in filling any gaps between the vacuum seal and the object surface.

The present patent application claims priority from U.S. ProvisionalPatent Applicant Serial No. 63/176,890, filed on Apr. 20, 2021, entitled“Portable vacuum gripper”, of the same inventors, hereby incorporated byreference in its entirety.

BACKGROUND OF THE INVENTION

Suction devices, such as vacuum grippers, can be used to grip forlifting flat objects using vacuum. The suction devices can includesuction cups in which a partial vacuum, e.g., an air pressure lower thanthe atmospheric pressure, is produced to adhere the suction devices tothe flat objects. The vacuum grippers typically require a seal between asurface of the vacuum gripper and a contacting surface on the object.

FIGS. 1A-1B illustrate examples of prior art vacuum grippers. In FIG.1A, a vacuum gripper 100 includes a vacuum seal 130, e.g., a flexiblematerial such as rubber, which can contact a surface of the object tomake a seal with the object surface. The vacuum gripper 100 furtherincludes a handle 110 for holding the vacuum gripper.

FIG. 1B shows another configuration of a vacuum gripper 100*, whichincludes two vacuum seals 130 connected by a handle 110. The vacuumgripper 100* also includes manual actuators for forming a vacuum underthe vacuum seals 130.

SUMMARY OF THE EMBODIMENTS

In some embodiments, the present invention discloses a vacuum gripperfor gripping an object surface using vacuum suction. The vacuum gripperis a portable vacuum gripper, e.g., having a handle to be carried by aperson, with or without attaching to an object. With the handle, theportable vacuum gripper can be used for hand carry small objects. Inaddition, the portable vacuum gripper has multiple hookable elementsconfigured to be coupled to cables having hook ends. With the hookableelements, the portable vacuum gripper can be used for hoisting largeobjects.

The vacuum gripper is configured for safe transportation of objects, byproviding a long term vacuum generation capability through a controllerregulating an air extraction mechanism to conserve and maximizing theusage of battery energy. The vacuum gripper is further configured withsafeguard components to prevent vacuum loss when the vacuum gripper istransporting an object. The safeguard components include a rechargingmechanism for recharging the battery on the job, for example, through aportable power pack or through an integrated power generator. Thesafeguard components include a manual vacuum pump for generating neededvacuum suction in the event that the battery-operated vacuum pump ismalfunctioned.

The vacuum gripper is configured with an elastic deformable vacuum sealfor gripping objects with irregular surfaces, such as rough surfaces, orsurfaces with steps, grooves, or bumps. The deformable vacuum seal canbe compressible and stretchable to conform to the irregular surface ofthe objects.

In some embodiments, the vacuum gripper includes a base elementconfigured to expose top portions of the vacuum seal for ease ofassisting the conformity of the vacuum seal with the object surface. Forexample, a press rod can be used to press on top areas of the vacuumseal, at locations that the vacuum seal forms gaps with the objectsurface. With the press rod pressing on a top side of the vacuum seal,the bottom side of the vacuum seal can protrude to fill in the gaps.

The vacuum seal is configured to allow a transfer of material, e.g., aprotrusion at the bottom side when the top side is depressed. Forexample, a flexible layer with higher hardness can be disposed on acompressible layer of the vacuum seal, which can improve the materialtransfer for gap filling when pressed. Alternatively, multilayercompressible seal can be used with the top portion having higherhardness than the bottom portion.

The vacuum gripper can have a press rod, configured to be stored in thevacuum gripper, which can be used for pressing on the vacuum seal toimprove the conformity with the object surface.

In some embodiments, the vacuum gripper includes an array of movablepins disposed on the vacuum seal at the periphery of the vacuum gripper.Pins of the pin array can be pressed to push the vacuum seal toward theobject surface, for filling gaps between the vacuum seal and the objectsurface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1B illustrate examples of prior art vacuum grippers.

FIGS. 2A-2G illustrate a portable vacuum gripper configuration accordingto some embodiments.

FIG. 3 illustrates an explode view of a portable vacuum gripperaccording to some embodiments.

FIGS. 4A-4B illustrate flow charts for forming a portable vacuum gripperaccording to some embodiments.

FIGS. 5A-5C illustrate flow charts for operating a portable vacuumgripper according to some embodiments.

FIGS. 6A-6B illustrate a configuration for lifting an object with thevacuum gripper according to some embodiments.

FIGS. 7A-7B illustrate flow charts for operating a vacuum gripperaccording to some embodiments.

FIGS. 8A-8B illustrate a configuration for a vacuum seal in a portablevacuum gripper according to some embodiments.

FIGS. 9A-9B illustrate a configuration for a vacuum seal according tosome embodiments.

FIGS. 10A-10B illustrate a multilayer configuration for a vacuum sealaccording to some embodiments.

FIGS. 11A-11B illustrate a gradually composite vacuum seal according tosome embodiments.

FIGS. 12A-12B illustrate a vacuum seal with a flexible bottom layeraccording to some embodiments.

FIGS. 13A-13B illustrate a configuration for a vacuum seal according tosome embodiments.

FIGS. 14A-14B illustrate a vacuum gripper formation according to someembodiments.

FIGS. 15A-15I illustrate configurations for a vacuum seal according tosome embodiments.

FIG. 16 illustrates a formation process for a vacuum seal according tosome embodiments.

FIGS. 17A-17D illustrate flow charts for forming and operating a vacuumseal in a portable vacuum gripper according to some embodiments.

FIGS. 18A-18C illustrate configurations for localized pressing on avacuum seal according to some embodiments.

FIGS. 19A-19C illustrate a configuration for a flexible support for aflexible layer according to some embodiments.

FIGS. 20A-20B illustrate a formation and operation of a flexible supportaccording to some embodiments.

FIGS. 21A-21C illustrate a configuration of a vacuum gripper having baseopenings according to some embodiments.

FIG. 22 illustrates a flow chart for forming a vacuum gripper withopenings according to some embodiments.

FIG. 23 illustrates a process for operating a vacuum gripper withopenings according to some embodiments.

FIGS. 24A-24E illustrate configurations for the coupling between a baseelement and a flexible layer according to some embodiments.

FIG. 25 illustrates a process for forming a vacuum gripper according tosome embodiments.

FIGS. 26A-26H illustrate configurations of a vacuum seal according tosome embodiments.

FIGS. 27A-27I illustrate configurations for a vacuum seal according tosome embodiments.

FIG. 28 illustrates a process to form a vacuum gripper according to someembodiments.

FIGS. 29A-29B illustrate a portable vacuum gripper having seal deformingcomponents according to some embodiments.

FIGS. 30A-30D illustrate configurations for seal deforming componentsaccording to some embodiments.

FIGS. 31A-31C illustrate configurations for seal deforming componentsaccording to some embodiments.

FIG. 32 illustrates a process for forming a vacuum gripper having a pinarray according to some embodiments.

FIGS. 33A-33D illustrate flow charts for operating seal deformingcomponents in a portable vacuum gripper according to some embodiments.

DETAILED DESCRIPTION OF THE EMBODIMENTS

In some embodiments, the present invention discloses a portable vacuumgripper using suction for lifting objects. The portable vacuum grippercan include a body having a hollow cavity for forming a vacuum, e.g.,having an air pressure lower than the atmospheric pressure within thecavity. The vacuum gripper is configured to grip the object, at theobject surface, using the vacuum formed in the cavity. The body of theportable vacuum gripper can have components configured to lifting, suchas a handle for a manual lifting, or one or more hooks for lifting theobject using connected cables.

The vacuum gripper has a high surface area for increasing suction, and alow volume cavity volume for fast response, e.g., fast pressurereduction. Also, the vacuum gripper is configured to be coupled toirregular surfaces by having a vacuum seal designed for betterconforming to the irregular surfaces. In addition, the vacuum gripper isdesigned with power saving features for long term usages, such as acontroller to regulate a vacuum pump to reduce battery consumption,together with a manual or portable battery recharge to prolong thevacuum gripper capability when the battery runs out.

The portable vacuum gripper can include a seal extending around aperiphery of the hollow cavity for sealing the with an object surface.Using deformable materials, such as highly elastic deformable, e.g., atleast mostly returning to the original shape after being deformed,including compressible and stretchable characteristics for the vacuumseal element, the portable vacuum gripper can be used on irregularsurfaces, such as non smooth surfaces including rough surfaces, surfaceswith steps, or surfaces with grooves, of objects while still obtaining avacuum level.

The portable vacuum gripper can include a vacuum generating system,e.g., an air extraction mechanism, such as a vacuum pump using a motorpowered by a power source, such as by a battery pack. A controller canbe included for controlling the vacuum pump, such as for automaticallymaintaining a vacuum level in the hollow cavity. For example, thecontroller can be configured to turn off or slow down the vacuum pumpwhen the vacuum level reaches a predetermined level, e.g., when thepressure in the cavity reduces to the predetermined pressure level. Thecontroller can be configured to turn on or speed up the vacuum pump whenthe vacuum level drops below the predetermined level, e.g., the pressurein the cavity is higher than the predetermined pressure level. Apressure gauge can also be included, to provide visual indication of thevacuum level, e.g., the below-atmospheric pressure of the hollow cavityindicating the vacuum level.

As used herein, the term “vacuum level” is used to mean“lower-than-atmospheric pressure level”, and thus can be usedinterchangeable with “pressure level”, since a vacuum is an environmentin which there is less air as compared to the atmosphere, and thus avacuum level is a pressure level having lower than the atmosphericpressure. Specifically, a vacuum level is a pressure level lower thanthe atmospheric pressure, and a pressure level can be a pressure levellower, similar, or higher than the atmospheric pressure.

In some embodiments, the portable vacuum gripper can include a manualcharger system for charging the battery pack. For example, the manualcharging system can include a motor configured to generate a voltagewhen being rotated by a manual handle. The manual charging system caninclude a portable battery back, which can be connected to the batteryof the vacuum gripper to charge the battery. The manual charging systemcan ensure that the portable vacuum gripper can have power to maintainthe vacuum level, for example, when the vacuum gripper is gripping anobject to lift the object. The manual charging system can thus prolongthe gripping ability, by supplying power to the battery, for the vacuumgripper to at least finish the gripping and lifting job.

In some embodiments, the vacuum gripper can have a battery alarm toalert an operator about a potential problem with the battery, such as alow power level for the battery. The alarm can be a beeping sound, or aflashing light, or an indicator light.

In some embodiments, the portable vacuum gripper can include a manualpumping system for pumping air from the hollow cavity, e.g., to maintainthe vacuum level. For example, the manual pumping system can include apiston-cylinder configuration in which an operator can push on thepiston to pump air out of the cavity. The manual pumping system canensure that the portable vacuum gripper can maintain the vacuum level,for example, by an operator pumping the manual pump when the batterypack runs out of power and when the vacuum level is reduced, e.g., thepressure is higher than the predetermined pressure level due to, forexample, a gradual air leak. The manual pumping system can ensure thatthe portable vacuum gripper can maintain the vacuum level, for example,when the vacuum gripper is gripping an object to lift the object. Themanual pumping system can thus prolong the gripping ability, by manuallyextracting air from the cavity to maintain the vacuum level in thecavity, for the vacuum gripper to at least finish the gripping andlifting job. The manual pumping system can be an alternative, or anaddition to the manual charging system, which can assist the vacuumgripper when there is no portable battery pack available.

In some embodiments, the vacuum gripper can have a vacuum alarm to alertan operator about a potential problem with the vacuum level in thecavity, such as a high pressure level for the cavity. The high pressurelevel of the alarm can be lower than the pressure level for the vacuumpump to turn on, which can provide adequate time for the operator tofind a remedy. The vacuum alarm can be coupled to the battery alarm, forexample, the vacuum alarm is disabled when there is enough power in thebattery, since the vacuum pump can restore the vacuum level in thecavity. Only when there is no battery, the vacuum alarm can be activatedto alert the operator.

In some embodiments, the portable vacuum gripper can include componentsconfigured to selectively pushing on portions of the vacuum seal. Forexample, when sealing a step surface, the components can exert a forceon the lower step surface area and at the vicinity of the step, toensure that the vacuum seal is contacting the step surface without orwith minimum gaps, e.g., to minimize air leak. The components caninclude a pressurized pocket disposed along the length of the vacuumseal, which can push on the areas of the seal disposed on the surface ofthe lower step areas. The components can include an array of pinsdisposed along the length of the vacuum seal, which can allow anoperator to push on selective pins to form a complete seal.

General Configuration of a Vacuum Gripper

In some embodiments, a portable vacuum gripper can include a body or abase element for housing a motorized vacuum pump with a battery pack anda manual vacuum pump, together with a handle for holding the gripper,features for mounting a pressure gauge and a vacuum release button. Theportable vacuum gripper can include a seal extending around a peripheryof the body for sealing a vacuum between the gripper and an object.

FIGS. 2A-2G illustrate a portable vacuum gripper configuration accordingto some embodiments. FIG. 2A shows a perspective view of the portablevacuum gripper 200 viewed from above, showing a body or base 211 of thegripper, together with other components such as the motorized pump 220,the manual pump 221, the gripper handle 210 housing a battery pack, anda manual vacuum release button 212. There are other components, such asa power switch 220A for turning on or off the motorized pump 220,hookable elements 226 for coupling with lifting cables, and pressuregauge 223 for monitoring the pressure or vacuum level in the cavity. Thepressure gauge can allow detections of proper or poor operations of thevacuum gripper, for example, by showing the vacuum pressure level in thecavity. For vacuum level below an indicator mark on the pressure gauge,the vacuum gripper has adequate vacuum suction to hold and lift theobject. For vacuum level above the indicator mark, the vacuum gripperdoes not have adequate vacuum suction. Inspection of the vacuum grippershould be performed, such as checking for proper seal with the objectsurface, or for wear and tear of the vacuum seal element.

FIG. 2B shows a perspective view of the portable vacuum gripper 200viewed from below, showing the seal 230 surrounding a hollow cavity 215.

In operation, the portable vacuum gripper can be placed on a surface ofan object to be lifted, with the seal 230 contacting the object surface.The vacuum pump can be activated, e.g., turning on the motorized vacuumpump or manually pumping the manual vacuum pump, to evacuate air fromthe cavity 215, to form a vacuum in the cavity 215, e.g., to generate apressure level in the cavity that is less than the ambient atmosphericpressure. The vacuum cavity can generate a suction force to adhere theportable vacuum gripper to the object. Views from cut lines AA and BBare discussed in later sections.

In general, the vacuum gripper 200 can include a rigid base element 211and a loop-shaped vacuum seal element 230. The seal element 230 isattached at least indirectly to the base element. The seal element 230is elastically deformable, for example, compressible when being pressed,and stretchable when encountering roughness on the object surface toconform to the object surface. The vacuum level in the cavity can begenerated by an air extraction mechanism, such as a motorized vacuumpump, e.g., a pump configured for extract gas from the cavity.

The vacuum seal element 230 can surround a periphery of the base element211. In some embodiments, the vacuum seal element can be smaller thanthe base element, thus there is an extended portion of the base elementextending from the vacuum seal element.

FIG. 2C shows a cross section according to cut A-A through a middle ofthe portable vacuum gripper and FIG. 2D shows a cross section accordingto cut B-B through a portion near an edge of the portable vacuumgripper.

A portable vacuum gripper 200 can include a body 211, which can includea handle 210 on a body portion. The handle 210 can be configured tohouse a motorized pump 220 and a manual pump 221 at two sides, and tohouse a battery pack 222 in the handle portion. The body 211 can beconfigured to house a manual vacuum release button 212, a pressure gauge223, and a controller 224 for maintaining the vacuum level in the cavity215. A manual charging system 213 can be included for manually chargingthe battery. The manual charging system can include a motor having ahandle to rotate a shaft of the motor. The motor output can be coupledto a circuitry, which is coupled to the battery pack 222, to generate asuitable voltage for charging the battery pack 222. A battery chargerconnector 222A can be provided for charging the battery, for example,through a portable power source, such as a portable battery pack.

A vacuum seal 220 can be coupled to a bottom portion of the body, suchas surrounding a periphery of the bottom surface of the portable vacuumgripper. In general, the vacuum seal 220 can have a loop shape seal,such as a ring. In operation, the vacuum seal can be disposed on anobject surface, to form a close cavity 215. The vacuum seal can be madeof a compressible and stretchable material, to allow the portable vacuumgripper to adhere to objects having an irregular surface, such as arough surface, a step surface, a grooved surface, or a surface havingcracks or grooves.

The portable vacuum gripper can include seal stoppers or a filler 214,disposed in the cavity at a bottom portion of the portable vacuumgripper. The seal stopper 214 can be configured to stop the compressionof the vacuum seal 220, for example, by having a non-compressiblematerial or a material having less compressible than the vacuum seal.The seal stopper can also be configured as a filler for the cavity, forexample, to reduce the volume of the cavity without changing the contactsurface area of the cavity with the object surface. The seal stopper canbe configured with minimum surface area facing the object surface, suchas having channels along the bottom surface area. Thus, in operation,when the vacuum seal is compressed under the vacuum force, the vacuumseal compression is stopped at the seal stopper 214.

FIG. 2E shows a cross section through a middle of the portable vacuumgripper. FIG. 2F shows a cross section through a manual pump. FIG. 2Gshows a cross section through a motorized pump of the portable vacuumgripper.

A portable vacuum gripper 200 can include a body 211, which can includea handle 210 having a U shape to house a motorized pump 220, a manualpump 221, and a battery pack 222. A vacuum seal 220 can be coupled to abottom portion of the body 211.

The manual vacuum pump can be configured to evacuate air in a cavity ofthe portable vacuum gripper. The pumping action can include a pushingdown on a pump button 221A, with the spring 221B configured to returnthe pump button to the original position. Thus, by repeatedly pushing onthe pump button, the air in the cavity can be evacuated to form a vacuumcavity.

The motorized pump 220 can be connected to the battery pack 222 througha power witch 220A, which can be used to manually turn on or off themotorized pump. The motorized pump can also be controlled by acontroller (not shown), to regulate the vacuum level in the cavity. Themotorized pump can include an on-off motor, e.g., a motor can be turnedon or off, or a variable motor, e.g., a motor can have its speedregulated.

The portable vacuum gripper can include a pressure gauge for monitoringthe vacuum level in the cavity, e.g., the pressure level below theatmospheric pressure. The portable vacuum gripper can include a manualvacuum release button, which can be coupled to a seal to a releaseconduit. When the manual vacuum release button is pressed, the seal isopen to allow air to enter the cavity, raising the pressure n thecavity, e.g., reducing the vacuum level. When the manual vacuum releasebutton is released, a spring can push back on the button to re-engagethe seal to stop the air flow.

Exploded View

FIG. 3 illustrates an explode view of a portable vacuum gripperaccording to some embodiments. A portable vacuum gripper 300 can includea base plate 1, which, as shown, is a rectangular plate having roundedcorners. The bottom side of the base plate 1 can be hollow havinggrooves to accept the vacuum seal 21 and other seals. The base plate 1can have reinforced ridges. The top side of the base plate 1 can haveattachment ridges for connecting to a handle 2 and 3, and othercomponents such as a support plate 23. The base plate 1 can be made fromlight materials such as plastic or fiber glass. The base plate can becoupled to the handle and support plate through screws 19, 20 witho-ring 16. On the base plate, there can be a vacuum gauge 15.

A portable vacuum gripper 300 can include a handle configured into 2portions 3 and 4, having U shape and can be assembled together usingscrews 12. Inside the handle, there is a hollow area to house a batterypack, a motorized pump 5, a manual pump, and a controller board 35.There can be a door for access to the battery pack. On the handle, thereare a button 29 for vacuum release and a button 11 for air evacuationusing a motorized pump 5. The handle can be coupled to the base platethrough screws 7. Under the vacuum release button 29, there can be aspring 14, an o-ring 13, and an air blocker 30. The support plate 23 canbe configured for the attachment of hooks 17, for handling the objectcoupled to the portable vacuum gripper.

In some embodiments, the vacuum gripper includes an air extractionmechanism configured to remove air (or gas) from the cavity between theobject surface and the vacuum gripper, in order to create a vacuum thatcan couple the object to the vacuum gripper. The air extractionmechanism can include an air pump, e.g., a motor configured to move airfrom the cavity to the outside ambient. Other devices can be used, suchas an impeller or a compressed air vacuum generator using a Venturinozzle.

The motorized air pump can be configured to operate variably, e.g.,gradually power reduction or running intermittently, to conserve power,e.g., to prolong the gripping ability of the vacuum gripper so that thevacuum gripper will not lose its grip when holding, lifting, or movingthe object. For example, a pressure sensor coupled to a controller canbe included to monitoring the pressure, e.g., the vacuum level or thevacuum pressure, or the rate of pressure in the cavity.

In the intermittent or pulse mode, when the cavity pressure is below afirst predetermined operating pressure level, or when the cavitypressure reaches steady state, e.g., indicated by a low rate of changeof the pressure, such as a rate of change is below a first predeterminedoperating rate of change level, the motorized pump stops. When thecavity pressure is higher than a second predetermined operating pressurelevel, or when the rate of change of the pressure is above a secondpredetermined operating rate of change level, the motorized pumpre-starts.

In the gradually running mode, the power supplied to the motorized pumpcan be dependent on the monitored vacuum pressure. When the vacuumpressure is high, e.g., low vacuum level, the motorized pump can run onfull power to quickly reduce the pressure. When the cavity pressure isbelow the first predetermined operating pressure level, or when the arate of change is below the first predetermined operating rate of changelevel, the motorized pump can run on minimum power, e.g., enough powerto maintain the vacuum pressure level or to maintain the rate of changeof vacuum pressure.

In some embodiments, an air extraction assembly includes a motorizedpump, a battery to supply power to the motorized pump, a pressure sensorto detect a pressure level in the cavity, and a controller programmed tooperate the motorized pump based on the detected pressure level due tothe pressure sensor. The controller is programmed to conserve power,e.g., reduce the power consumption of the motorized pump to a minimumlevel.

The vacuum gripper can also include switch buttons, for example, to turnon or turn off the vacuum pump. Further, the vacuum gripper canoptionally include a release button to introduce air into the cavity,for releasing the vacuum to remove the object from the vacuum gripper.The vacuum gripper can also optionally include a pressure gauge formonitoring the vacuum pressure, and a battery gauge for monitoring thebattery level.

In some embodiments, the vacuum gripper is configured to ensure anon-failure status of the vacuum force, so that the vacuum gripper cansafely lift and deliver the object without a sudden lost of vacuum. Thevacuum gripper can have a power conserving vacuum pump mechanism,controlled by a controller based on a pressure sensed by a pressuresensor. A vacuum pump can draw power from a battery, to maintain thevacuum suction force on the object.

In some embodiments, the vacuum gripper includes an alarm configured toalert the operator about the status of the vacuum gripper. For example,the alarm can be a low battery power alarm, which can provide an alarmsound, an alarm flashing or steady light to notify the operator of thelow battery status. An operator then can manually recharge the battery,to ensure that the vacuum gripper can have enough vacuum power to finishthe current job. For example, the vacuum gripper can be used to hold apanel to be transported to a destination. During the transport, the lowbattery alarm can generate an alarm, so that the operator can manuallycharge the battery for the vacuum gripper to finish transporting thepanel without losing vacuum.

The manual battery recharge can include a power bank, e.g., a portablebattery configured to charge the battery of the vacuum gripper. Theoperator can connect the portable battery charger to the battery of thevacuum gripper for charging the battery. Alternatively, or additionally,the manual battery recharge can include a manual power generator, suchas a motor having a crank coupled to the battery of the vacuum gripper.By rotating the crank, the motor can turn to generate a voltage forcharging the battery. The low battery alarm can be an early alarm, e.g.,determined to sound the alarm when there is still enough power for themotorized pump to run for a while, such as for 10-20 minutes, which canallow adequate time for the operator to operate the manual chargingsystem.

The alarm can be a low vacuum alarm, e.g., when the pressure in thecavity is higher than a predetermined alarm pressure level. In general,the alarm is generated when the motorized pump cannot reduce the cavitypressure, such as when the battery powering the pump has no power, orwhen the motorized pump is defective.

An operator then can manually correct the alarm error, to ensure thatthe vacuum gripper can have enough vacuum power to finish the currentjob. For example, in the case of low vacuum due to low battery, theoperator can operate a manual battery recharge, such as a connecting aportable battery recharger or turning a crank to generate power torecharge the battery.

The vacuum gripper can include a manual vacuum pump in parallel with themotorized pump. Thus, in the case of motorized pump failure, theoperator can operate the manual vacuum pump to bring back the vacuumlevel. The operator can repeatably operate the manual vacuum pump tomaintain the vacuum pressure level in the cavity until the vacuumgripper finish the current job, such as to finish transporting the panelheld by the vacuum gripper vacuum suction.

In some embodiments, the vacuum gripper is a portable vacuum gripper,e.g., having a power source such as a battery for powering the motorizedvacuum pump. The motorized vacuum pump and the battery can be housed ina handle coupled to a base element of the vacuum gripper to form acompact arrangement. A manual pump or a motorized battery recharge canalso be housed in the handle. For example, the handle can include ahandle bar coupled to two connecting bars. The motorized pump and themanual pump can be disposed in the connecting bars, with easy and shortaccess to the cavity for air extraction. The battery powering themotorized pump can be disposed in the handle bar. The controller and theoptional motorized battery recharge can also be housed in a portion ofthe handle bar, or in the connecting bars.

In some embodiments, the vacuum gripper can include a filler materialwithin the cavity, to reduce the volume of the cavity for fast pumpingaction. The filler material can be coupled to the underside of the baseelement. The filler material can also function as a seal stopper, e.g.,stopping the seal material from being over-compressed. The fillermaterial can include rigid materials to provide a structural integrityto the base element. The filler material is also configured to notaffect the vacuum area, e.g., the contact area between the vacuum sealelement and the object surface.

In some embodiments, the vacuum seal can be made from a flexiblematerial, such as a ring of soft elastomer, silicone, rubber,closed-cell foam, or pressured thin-walled rubber tubes. The vacuum sealmaterial can include a cellular or granular material, such as rubber andplastics, covered with a thin protective layer. The material of thevacuum seal can be chosen so that the vacuum seal can be elasticallydeformable to enable the bottom seal surface to conform to the objectsurface. For example, when pressed against a step surface, the seal canbe compressed more at the higher step area. Further, the seal can bestretch at the step corner to allow the seal to flow around the stepcontour, for sealing against the step surface.

In some embodiments, the elastic deformable material of the vacuum sealelement can include flexible, compressible, and stretchable materialssuch as silicone, rubber, or close-cell foams of silicone or rubber. Thedeformable materials are flexible enough to conform to an irregularsurface, such as an uneven surface having steps and groove, or a roughsurface. Close-cell foams can be highly compressible to conform to theirregularities of the surface. Further, close-cell foam can have highelasticity, e.g., capable of returning or spring back to the originalshape when the compressive load is removed.

In some embodiments, the elastic deformable material can include apneumatic or hydraulic element, which includes an outer layer of aflexible and stretchable material such as silicone or rubber, and whichhas a cavity filled with a fluid, such as air. The pressure in thecavity of the pneumatic or hydraulic element can be adjustable, to beoptimized for the conformity of the vacuum seal element with thenon-smooth surface of the object.

Formation of a Vacuum Gripper

FIGS. 4A-4B illustrate flow charts for forming a portable vacuum gripperaccording to some embodiments. In FIG. 4A, operation 400 forms a vacuumgripper for gripping an object surface. The vacuum gripper includes abase element, a close-loop vacuum seal element coupled to a surface ofthe base element to form a cavity when contacting the object surface,and a vacuum pump coupled to the base element and fluidly communicatedwith the cavity for evacuating air in the cavity.

In FIG. 4B, operation 420 forms a vacuum gripper for gripping an objectsurface. The vacuum gripper includes a base element, a close-loop vacuumseal element coupled to a surface of the base element to form a cavitywhen contacting the object surface, a vacuum pump coupled to the baseelement and fluidly communicated with the cavity for evacuating air inthe cavity, a battery for supplying power to the vacuum pump, a releasemechanism for introducing air into the cavity, a manual charger formanually recharging the battery, a manual pump for manually evacuatingair in the cavity, a handle coupled to the base element, a battery gaugefor monitoring a battery level, a pressure gauge for monitoring apressure in the cavity, hookable elements coupled to the base elementfor lifting the vacuum gripper with the object, and a controller forregulating the vacuum pump to maintain a desired pressure in the cavityand for notifying of low battery levels. Some elements can be optional.

In some embodiments, a vacuum gripper can be formed for gripping anobject surface. The vacuum gripper includes a base element. The baseelement can be a plate, which can serve as a body for the vacuumgripper. For example, the vacuum seal element can be coupled to one sideof the base element, such as a bottom side to be facing the object. Ahandle housing the air extraction mechanism can be coupled to anopposite side of the base element, such as a top side facing anoperator. Other components can be mounted on the base element, such asthe indicator of the pressure gauge, and hook elements for coupling thevacuum gripper to a hoist cable.

The vacuum gripper includes a vacuum seal element coupled directly orindirectly to the base element. For example, the vacuum seal element canbe coupled directly to the base element, such as using an adhesive. Thevacuum seal element can be coupled indirectly to the base element, suchas through a flexible layer, also using an adhesive. The vacuum sealelement is configured to form a vacuum cavity with the base element andthe surface of the object. The vacuum seal element can be disposedaround a periphery of the base element to increase a contact surfacearea with the object surface.

The vacuum seal element can include an elastic deformable material withthe deformable characteristic used to provide conformity with irregularobject surfaces, such as rough surfaces, or surfaces with grooves orsteps. The deformable seal element can be stretched and compressed tofollow the variations of the object surface, so that an adequate vacuumlevel can be formed within the cavity.

The vacuum gripper includes an air extraction mechanism coupled to thetop side of the base element and in fluid communication with the cavity.The air extraction mechanism is configured to extract gas, such as air,from the cavity to create a suction force for coupling the objectsurface to the vacuum gripper. The air extraction mechanism can includea motor configured to pump air out of the cavity, such as a motorizedair pump. The air extraction mechanism can include other systemconfigured to remove air from the cavity, such as an impeller, or a highflow Venturi construction. The air extraction mechanism can be housed ina handle, e.g., a hollow handle can be coupled to the base element, withthe air extraction mechanism disposed within the hollow portion of thehandle.

The vacuum gripper includes a power source configured to provide powerto the air extraction mechanism. The power source can be a battery, suchas a rechargeable battery. The power source can be housed in the handlethat houses the motorized pump. For example, the handle can have a Cshape, with a middle portion parallel to the base element and coupled totwo bars perpendicular to the base element at two end of the middleportion. The middle portion and the two end bars are hollow to house theair extraction mechanism, such as an end bar is configured to house themotorized pump and the middle portion is configured to house thebattery. The battery can be a rechargeable battery, with a connectorconfigured to accept a charger, such as a portable charger for chargingthe battery on the field, e.g., without requiring an outlet.

The vacuum gripper includes a controller configured to regulate the airextraction mechanism. The power regulation can be configured to saveenergy, e.g., to prolong the vacuum generation in the cavity so that thevacuum gripper can hold and transport a load for longer time. In anintermittent power regulation, the controller is configured to turn offthe air extraction mechanism when a pressure level in the cavity reachesa predetermined pressure level or when a rate of pressure reduction inthe cavity reaches a predetermined level. The controller is alsoconfigured to turn on the air extraction mechanism when a pressure levelin the cavity is below the predetermined pressure level. Alternatively,the power regulation can use a variable power motor for the motorizedpump, e.g., the motorized pump can run at different power levels, suchas a full power for a maximum air extraction, or a lower power for lowerair extraction capability. The controller can run the variable motorbased on the cavity pressure, such as higher power when the cavitypressure or the rate of pressure change is high, and lower power whenthe cavity pressure or the rate of pressure change is low. When thepressure reaches steady state, e.g., when the rate of pressure change issmall, the controller can run the motor at a base power, which is enoughto compensate for the pressure loss to maintain the proper vacuum levelin the cavity.

The vacuum gripper includes an alarm, configured to provide an alarmwhen a power level of the battery is below a predetermined battery valueor when the pressure level in the cavity is above a predeterminedpressure value. The alarm can alert an operator to care for the vacuumgripper, especially when the vacuum gripper is in use, e.g., holding andlifting or transporting an object.

The vacuum gripper includes a manual mechanism configured to maintain anoperation of the vacuum gripper, e.g., to address the cause of the alarmto clear the alarm to maintain the operation of the vacuum gripper. Inthe case of low battery alarm, the manual mechanism can include a remoteportable power source, or an integrated power generator for charging thebattery. For example, the manual mechanism can be configured to chargethe power source from an external power supply by an operator using aportable power source to connect to the battery for charging thebattery. The manual mechanism can be configured to manually charging thebattery by an operator using a manual charger mechanism such as a manualpower generator.

In the case of low vacuum alarm, e.g., high pressure in the cavity ofthe vacuum gripper, the manual mechanism can include an integratedmanual pump configured to extract gas from the cavity to lower thepressure level by an operator using a manual pump to pump air from thecavity.

The vacuum gripper can also include other components, such as an airrelease mechanism coupled to the base element and in fluid communicationwith the cavity to release gas or air from the cavity upon beingactivated, hookable elements coupled to the base element, and configuredto be coupled to a hoist mechanism to lifting the object, and a bottomflexible layer coupled to the bottom of the vacuum seal element, e.g.,to the surface of the vacuum seal facing the object surface, configuredto prolong the life of the vacuum seal element by being a material moredurable or more abrasion-resistant than that of the vacuum seal element.

Operation

FIGS. 5A-5C illustrate flow charts for operating a portable vacuumgripper according to some embodiments. In operation, the portable vacuumgripper is moved to position at a middle area of an object, such as apanel, to be transported. The portable vacuum gripper is then pushed sothat the vacuum seal is compressed onto the surface of the object. Themotorized pump is turned on to generate a vacuum n a cavity between theportable vacuum gripper and the object surface. The motorized pump isturned on until the pressure gauge drops to a predetermined vacuumlevel. The portable vacuum gripper can be raised, for example, byholding on the handle or by attaching to the hooks on the portablevacuum gripper.

After the object is transported to the desired location, the vacuumrelease button can be pressed to allow air to enter the cavity, e.g.,releasing the vacuum pressure. The portable vacuum gripper and theobject can be separated. In the event of battery running out, the manualvacuum pump can be used to evacuate air. Alternatively, the manualcharger system can be used to recharge the battery.

In FIG. 5A, operation 500 turns on a motor for generating a vacuum sealfor the portable vacuum gripper until reaching a vacuum level. Operation510 automatically turns on the motor when a pressure is below the vacuumlevel. The motor can be automatically turned on and off to maintain thevacuum level.

In FIG. 5B, operation 530 turns on a motor for generating a vacuum sealfor the portable vacuum gripper. Operation 540 manually pumps the manualpump to generate a vacuum or to maintain the vacuum when the battery isout.

In FIG. 5C, operation 560 turns on a motor for generating a vacuum sealfor the portable vacuum gripper. Operation 570 manually turns a chargingsystem to charge a battery for the motor when the battery is out.

Hookable Elements

In some embodiments, the vacuum gripper can include hookable elements toconvert the vacuum gripper from a hand carrying gripper to a hoistcarrying gripper. The vacuum gripper has a handle, configured for anoperator to hand carrying an object vacuum coupled to the vacuumgripper. The vacuum gripper also has one or more hookable elements,which are configured to be hooked to cables from a hoist, such as froman overhead crane, to allow the hoist to lift and transport the object.The hookable elements can have a loop shape, such as a ring or an openhook, to be attached to a cable having a hook end. Other configurationscan be used, such as a bar coupled at both ends to the vacuum gripper,or a pin having a through hole.

FIGS. 6A-6B illustrate a configuration for lifting an object with thevacuum gripper according to some embodiments. In FIG. 6A, a vacuumgripper 600 is placed on an object, such as a flat panel 601. Themotorized pump is turned on, for example, by pressing the vacuum on 620Abutton. When the vacuum pressure is stable, the vacuum gripper isattached 602 to the panel 601. The vacuum gripper 600 has multiplehookable elements 620, in the form of flat rings, disposed around thevacuum gripper.

In FIG. 6B, cables 628 having hook end are coupled to the hookableelements 626. The other ends of the cables can be coupled to a hoist,which can exert a lifting force 603 to lift the panel.

FIGS. 7A-7B illustrate flow charts for operating a vacuum gripperaccording to some embodiments. FIG. 7A shows a process to machinetransport an object, such as a panel, using a vacuum gripper. Operation700 places a vacuum gripper on a surface of a panel. Operation 710 turnson the vacuum pump in the vacuum gripper to secure the vacuum gripper tothe panel. Operation 720 checks for adhesion between the vacuum gripperand the panel when the pressure gauge in the vacuum gripper indicates asuitable pressure level. Operation 730 couples cables having hook endsto the hookable elements of the vacuum gripper. Operation 740 lifts thecables for transferring the panel.

FIG. 7B shows a process to release the vacuum gripper after completingthe transportation. Operation 750 lowers cables coupled to hookableelements of a vacuum gripper so that a panel coupled to the vacuumgripper rests on a support. Operation 760 turns off the vacuum pump inthe vacuum gripper. Operation 770 releases the panel from the vacuumgripper by letting air into a vacuum coupling between the vacuum gripperand the panel. Operation 780 decouples the cables by removing the hookends from the hookable elements of the vacuum gripper.

Elastic Deformable Vacuum Seal Element

In some embodiments, a portable vacuum gripper can include a close-loopvacuum seal element for sealing a bottom surface of the portable vacuumgripper with the surface of an object to be transported. The vacuum sealcan be made of a single material or can be formed as composite materialsor layers.

FIGS. 8A-8B illustrate a configuration for a vacuum seal in a portablevacuum gripper according to some embodiments. FIG. 8A(a) shows aperspective view of the portable vacuum gripper 800 viewed from above,showing a vacuum seal 830, together with a body 811 of the gripper forhousing a motorized pump 820, a manual pump 821, and a handle 810. FIG.8A(b) shows a perspective view of the vacuum seal 830, which has theform of a close loop seal. The vacuum seal can have a cross sectionalarea of a rounded rectangle, having a width adequate for making a seal,and having a thickness adequate for handling irregular surfaces ofobjects. For example, the seal thickness can be greater than theirregular variation of the irregular surface, such as greater than thedepth of a groove on the irregular surface or greater than a step heighton the irregular surface.

In some embodiments, the vacuum seal can be made of a compressible andstretchable material. FIG. 8B(a) shows a response of the vacuum seal 831under a compressed force 840A. The vacuum seal 831 is compressed underthe compressed force 840A. The compressed factor can be up to 70%, e.g.,can be compressed an amount less than 10%, less than 20%, less than 30%,less than 40%, less than 50%, less than 60%, or less than 70% of theoriginal thickness.

FIG. 8B(b) shows a response of the vacuum seal 831 under a stretchedforce 840B. The vacuum seal 831 is stretched under the stretched force840B. The stretched factor can be up to 40%, e.g., can be stretched anadditional amount less than 10%, less than 20%, less than 30%, or lessthan 40% of the original width.

One Layer Vacuum Seal Element

FIGS. 9A-9B illustrate a configuration for a vacuum seal according tosome embodiments. In FIG. 9A, the vacuum seal 930 can have a solidconfiguration, e.g., having a solid material 931. The vacuum seal caninclude a flexible, e.g., compressible and stretchable, material 931such as rubber or elastomer. Due to the compressible and stretchablenature of the flexible material 931, the vacuum seal 931 can beconformed to grooved or step or irregular surface areas.

In FIG. 9B(a), the portable vacuum gripper 900 can be placed on a stepsurface of an object. The portable vacuum gripper 900 can include avacuum seal 930 coupled to a body 911 of the portable vacuum gripper900. The portable vacuum gripper 900 can be pushed down to make a sealbetween the vacuum seal and the step surface. In addition, the motorizedvacuum pump can be turned on to generate a vacuum in a cavity under theportable vacuum gripper.

In FIG. 9B(b), the vacuum seal can be compressed along the thickness ofthe seal due to the vacuum generation in the cavity of the portablevacuum gripper. The direction of the compression is perpendicular to thesurface of the object, thus the vacuum seal is compressed more 931* atthe higher step and compressed less 931** at the lower step of the stepsurface.

In addition, at the step corner, the vacuum seal material can bestretched, due to a side force 955, to fill in the step corner, so thatthe vacuum seal is conformed to the step surface to make a good sealwith the step surface. Thus, the vacuum seal can be used to formconformal seal with irregular surfaces of objects, such as stepsurfaces, groove surfaces, or rough surfaces.

Due to the uneven surface, e.g., the step, there can be a strong force956A on contact with the object surface at the higher portion of thestep, as compared to a weak force 956B on contact with the objectsurface at the lower portion of the step. The force difference canresult in different adhesion to the object surface, with strongeradhesion at the higher step portion and weaker adhesion at the lowerstep portion.

Multilayer Discrete Vacuum Seal Element

To reduce the force difference, a multilayer vacuum seal element can beused. The multilayer seal element can include different layers havingdifferent elastic deformation characteristics, such as highercompressibility and higher stretchability in bottom layers as comparedto top layers.

FIGS. 10A-10B illustrate a multilayer configuration for a vacuum sealaccording to some embodiments. A vacuum seal can be a composite seal,e.g., having multiple layers 1031, 1035, and 1036 with differentproperties. In FIG. 10A(a), the layers can have different compressibleproperties, e.g., can be compressed more or less for a same compressedforce. For example, layers 1031, 1035, and 1036 can have a samethickness and subjected to a same compressed force. The layer 1031 canbe compressed the most to become a very thin layer 1031*. The layer 1035can be compressed less to become a thin layer 1035*. The layer 1036 canbe compressed the least to become a thicker layer 1036*.

In FIG. 10A(b), the layers can have different stretchable properties,e.g., can be stretched more or less for a same stretched force. Forexample, layers 1031, 1035, and 1036 can have a same thickness andsubjected to a same stretched force. The layer 1031 can be stretched themost to become a very long layer 1031**. The layer 1035 can be stretchedless to become a long layer 1035**. The layer 1036 can be stretched theleast to become a shorter layer 1036**.

In FIG. 10B(a), a portable vacuum gripper 1000 can include a vacuum seal1030 coupled to a body 1011 of the portable vacuum gripper 1000. Thevacuum seal 1030 can include multiple layers 1031, 1035 and 1036 eachhaving a different compressed and stretched property. In addition, thehigher compressible and stretchable layer 1031 can be thicker than thelower compressible and stretchable layer 1035 and 1036.

The portable vacuum gripper 1000 can be placed on a step surface of anobject. The portable vacuum gripper 1000 can be pushed down to make aseal between the vacuum seal and the step surface. In addition, themotorized vacuum pump can be turned on to generate a vacuum in a cavityunder the portable vacuum gripper.

In FIG. 10B(b), the vacuum seal can be compressed along the thickness ofthe seal due to the vacuum generation in the cavity of the portablevacuum gripper. The direction of the compression is perpendicular to thesurface of the object, thus the vacuum seal is compressed more1031*/1035*/1036* at the higher step and compressed less1031**/1035**/1036** at the lower step of the step surface. The morecompressible and stretchable layers 1031 and 1035 are flexed more ascompared to the less compressible and stretchable layers 1035 and 1036,respectively.

In addition, at the step corner, the vacuum seal material can bestretched, due to a side force 1055, to fill in the step corner, so thatthe vacuum seal is conformed to the step surface to make a good sealwith the step surface. Thus, the vacuum seal can be used to formconformal seal with irregular surfaces of objects, such as stepsurfaces, groove surfaces, or rough surfaces.

Due to the multilayer seal, there can be a medium strong force 1056A* oncontact with the object surface at the higher portion of the step, ascompared to a medium weak force 1056B * on contact with the objectsurface at the lower portion of the step. For appropriate thicknesses ofthe layers in the multilayer seal, the force difference can be smalleras compared to a single layer seal.

Composite Seal with Gradually Varying Elastic Deformable Properties

To further reduce the force difference, a vacuum seal element havinggradually varying elastic deformable properties can be used. The gradualvarying seal element can include a composite layer having continuous orgradual different elastic deformation characteristics.

FIGS. 11A-11B illustrate a gradually composite vacuum seal according tosome embodiments. A vacuum seal can be a gradually composite seal, e.g.,having a gradually varying elastic deformable properties. In FIG. 11A, acomposite layer 1160 can have gradually different compressibleproperties. The composite layer 1160 can be compressed more 1160A undera high force, and can be compressed less 1160B under a lower force.

In FIG. 11B(a), a portable vacuum gripper 1100 can include a vacuum seal1130 coupled to a body 1111 of the portable vacuum gripper 1100. Thevacuum seal 1130 can include a gradual composite layer 1160.

The portable vacuum gripper 1100 can be placed on a step surface of anobject. The portable vacuum gripper 1100 can be pushed down to make aseal between the vacuum seal and the step surface. In addition, themotorized vacuum pump can be turned on to generate a vacuum in a cavityunder the portable vacuum gripper.

In FIG. 11B(b), the vacuum seal can be compressed along the thickness ofthe seal due to the vacuum generation in the cavity of the portablevacuum gripper.

In addition, at the step corner, the vacuum seal material can bestretched, due to a side force 1155, to fill in the step corner, so thatthe vacuum seal is conformed to the step surface to make a good sealwith the step surface. Due to the gradual composite seal, there can be aslightly strong force 1156A** on contact with the object surface at thehigher portion of the step, as compared to a slightly weak force 1156B**on contact with the object surface at the lower portion of the step,which can form similar pressure 1157B on the object surface. Forappropriate variation of the elastic deformable properties, the forcedifference can be smaller as compared to a single layer seal.

Flexible Layer in Bottom

In some embodiments, a durable layer can be disposed under the vacuumseal to protect the vacuum seal, especially when the vacuum sealincludes a foam material. The durable layer can be thin and flexible,e.g., stretchable, to follow the contour of the object surface.

FIGS. 12A-12B illustrate a vacuum seal with a flexible bottom layeraccording to some embodiments. A vacuum seal can be an elasticdeformable seal 1231, such as a single layer seal, a multilayer seal, ora gradually composite seal. In FIG. 12A, a vacuum seal includes acompressible layer 1231 coupled to a flexible layer 1261. Thecompressible layer 1231 can be an elastic deformable layer, such ascompressible and stretchable. For example, under a compressed force, thecompressible layer 1231 can be compressed to a compressed layer 1231*.The flexible layer can be thin and flexible, such as stretchable. Forexample, upon encounter a step, the flexible layer 1261 can be flexed toa flexed layer 1261* to match with the step surface of the object.

In FIG. 12B(a), a portable vacuum gripper 1200 can include a vacuum seal1230 coupled to a body 1211 of the portable vacuum gripper 1200. Thevacuum seal 1230 can include a compressible layer 1231 coupled to aflexible layer 1261.

The portable vacuum gripper 1200 can be placed on a step surface of anobject. The portable vacuum gripper 1200 can be pushed down to make aseal between the vacuum seal and the step surface. In addition, themotorized vacuum pump can be turned on to generate a vacuum in a cavityunder the portable vacuum gripper. At the step corner, the vacuum sealmaterial can be stretched, due to a side force 1255, to fill in the stepcorner, so that the vacuum seal is conformed to the step surface to makea good seal with the step surface.

In FIG. 12B(b), the vacuum seal can be compressed along the thickness ofthe seal due to the vacuum generation in the cavity of the portablevacuum gripper. The flexible layer can include a more durable materialthan the compressible layer, thus can prolong the lifetime of the vacuumgripper.

Rubber Tube Vacuum Seal

In some embodiments, the vacuum seal can include a pneumatic orhydraulic element such as a rubber tube. The rubber tube can becompressible and stretchable, together with having a bottom flexiblelayer of rubber.

FIGS. 13A-13B illustrate a configuration for a vacuum seal according tosome embodiments. In FIG. 13A, the vacuum seal 1330 can have a tubeconfiguration, e.g., having a cover 1332A surrounding an interior gas1332B. The vacuum seal can include a flexible, e.g., compressible andstretchable, cover material 1332A such as rubber or elastomer. Thevacuum seal can be hollow, e.g., filled with a gas 1332B such as air. Inaddition to the compressible and stretchable nature of the rubber tubeconfiguration of the vacuum seal, the air pressure in the vacuum sealarea 1332B can be configured to allow the vacuum seal to be conformed togrooved or step or irregular surface areas.

In FIG. 13B(a), the portable vacuum gripper 1300 can be placed on thesurface of an object. The surface can be an irregular surface, such ashaving a step configuration. The step surface can be shown with the stepexaggerated to illustrate the sealing nature of the portable vacuumgripper on a step surface. The portable vacuum gripper 1300 can includea vacuum seal 1330 coupled to a body 1311 of the portable vacuum gripper1300. At the beginning, the vacuum seal can touch the step surface orcan be deformed somewhat under the weight of the portable vacuumgripper.

The portable vacuum gripper 1300 can be pushed down to make a sealbetween the vacuum seal and the step surface. In addition, the motorizedvacuum pump can be turned on to generate a vacuum in a cavity under theportable vacuum gripper.

In FIG. 13B(b), the vacuum seal can be compressed along the thickness ofthe seal due to the vacuum generation in the cavity of the portablevacuum gripper. The direction of the compression is perpendicular to thesurface of the object, thus the vacuum seal is compressed more 1332* atthe higher step and compressed less 1332** at the lower step of the stepsurface.

In addition, at the step corner, the vacuum seal material can bestretched to fill in the step corner, so that the vacuum seal isconformed to the step surface to make a good seal with the step surface.Thus, the rubber tube vacuum seal can be used to form conformal sealwith irregular surfaces of objects, such as step surfaces, groovesurfaces, or rough surfaces.

FIGS. 14A-14B illustrate a vacuum gripper formation according to someembodiments. In FIG. 14A, operation 1400 forms a vacuum gripper forgripping an object surface. The vacuum gripper includes a base element,a close-loop vacuum seal element coupled to a surface of the baseelement to form a sealed cavity when contacting the object surface, avacuum pump coupled to the base element and fluidly communicated withthe cavity for evacuating air in the cavity.

The vacuum seal element includes a compressible material having agradual varying compressible property or multiple layers of differentcompressible properties. The gradual varying compressible property orthe multiple layers of different compressible properties are configuredto balance contact forces on the vacuum seal element with a heightvariation of the object surface. The vacuum seal element optionallyincludes a flexible layer coupled at a surface opposite the surface ofthe base element. The flexible layer includes a more abrasion-resistantmaterial than the compressible material of the vacuum seal element.

Alternatively, the vacuum seal element includes a pneumatic or hydraulicelement having a flexible layer forming a fluid filled cavity. Thepneumatic or hydraulic element has a fluid filled cavity pressureoptimized for a sealing of the vacuum seal element on a height variationobject surface. The vacuum gripper optionally includes a pumpingmechanism to adjust a pressure of the fluid filled cavity.

In FIG. 14B, operation 1420 generates a vacuum in a cavity of a vacuumgripper after coupling the vacuum gripper to a panel surface. Operation1430 presses on the vacuum gripper at irregular surface locations of thepanel surface to obtain a desired vacuum level.

Different Configurations

FIGS. 15A-15I illustrate configurations for a vacuum seal according tosome embodiments. A flexible thin layer 1534 can be disposed under avacuum seal or between multiple vacuum seals, such as on a rubber tubeseal 1532A/1532B, a solid material seal 1531, a multilayer material seal1531/1535/1536, or a seal having any combination of layers of rubbertube, solid material, multilayer material, or gradual varying material.

For example, FIG. 15A shows a flexible thin layer 1561 disposed under arubber tube seal having pressured air 1532B inside a rubber wall 1532A.FIG. 15B shows a flexible thin layer 1561 disposed under a seal havinglayers 1536, 1535, and 1531, each with different compressible andstretchable material. FIG. 15C shows a flexible thin layer 1561 disposedunder a seal having a layer 1531. FIG. 15D shows a flexible thin layer1561A disposed between a seal having layers 1535/1531 and a rubber tubeseal 1532A/1532B. FIG. 15E shows a flexible thin layer 1561A disposedbetween a seal having a layer 1531 and a rubber tube seal 1532A/1532B.FIG. 15F shows a flexible thin layer 1561A disposed between a sealhaving a rubber tube 1532A1 and a rubber tube seal 1532A. FIG. 15G showsa flexible thin layer 1561A disposed between a seal having a rubber tube1532A and a seal having layers 1535/1531, together with another flexiblethin layer 1561 under the seal having layers 1535/1531. FIG. 15H shows aflexible thin layer 1561 disposed under a seal having a rubber tube1532A and a seal having layers 1535/1531. FIG. 151 shows a flexible thinlayer 1561A disposed between two seals having rubber tubes 1532A1 and1532A, together with another flexible thin layer 1561 under the sealhaving a rubber tube 1532A.

FIG. 16 illustrates a formation process for a vacuum seal according tosome embodiments. Operation 1600 forms a vacuum gripper for gripping anobject surface. The vacuum gripper includes a base element, a close-loopvacuum seal element coupled to a surface of the base element to form asealed cavity when contacting the object surface, a vacuum pump coupledto the base element and fluidly communicated with the cavity forevacuating air in the cavity.

The vacuum seal element includes a compressible material having agradual varying compressible property. The vacuum seal element includesa compressible material having multiple layers of different compressibleproperties. The vacuum seal element includes a compressible structurehaving a pneumatic or hydraulic element having a flexible layersurrounding a fluid filled cavity. The vacuum seal element includes acompressible material on a flexible layer. The vacuum seal elementincludes a compressible material having a combination of two or morelayers of a gradual varying compressible property, multiple layers ofdifferent compressible properties, a pneumatic or hydraulic elementhaving a flexible layer forming a fluid filled cavity, or a flexiblelayer.

The layers of the vacuum seal element are optimized for a sealing of thevacuum seal element on a height variation object surface.

FIGS. 17A-17D illustrate flow charts for forming and operating a vacuumseal in a portable vacuum gripper according to some embodiments. Thevacuum seals are designed to be conformed to irregular surfaces, such asstep surfaces, groove surfaces, or rough surfaces.

In FIG. 17A, operation 1700 forms a seal for a vacuum gripper device.The seal can be configured to be compressible and stretchable. In someembodiments, the seal can include an air pocket, such as an air tube.The seal can include one layer of a compressible and stretchablematerial. The seal can include multiple layers of compressible andstretchable materials with different thicknesses. The seal can include acombination of one or more air tubes and one or more layers ofcompressible and stretchable materials with different thicknesses.

In FIG. 17B, operation 1720 presses a seal of a suction device on anirregular surface, wherein the seal is compressed more at higher surfaceareas and is stretched at lower surface areas so that the bottom surfaceof the seal is conformed to the irregular surface.

In FIG. 17C, operation 1740 presses a multilayer seal of a suctiondevice on an irregular surface, wherein bottom layers of the seal arecompressed and stretched more than top layers so that the bottom surfaceof the seal is conformed to the irregular surface.

In FIG. 17D, operation 1760 presses a flexible layer on a seal of asuction device on an irregular surface, wherein the flexible layer isconfigured for smoothly conformed to the irregular surface.

Localized Pressing on the Vacuum Seal for Better Conformity

In some embodiments, a flexible layer can be disposed on top of thevacuum seal element, e.g., between the base element and the vacuum sealelement. The flexible layer can be configured to assist in making thevacuum seal more conforming to the irregularities of the object surface.For example, by pressing on the flexible layer, the vacuum seal canprotrude from the opposite side to fill in any gap with the objectsurface. Thus, the flexible layer can be configured to be deformed witha less localized pattern than the elastic deformable material under apoint indentation. Alternatively or additionally, the flexible layer canbe configured to be protruded more in an opposite surface than theelastic deformable material under the point indentation. For example,the flexible layer can include a higher hardness than the elasticdeformable material of the vacuum seal.

FIGS. 18A-18C illustrate configurations for localized pressing on avacuum seal according to some embodiments. In FIG. 18A, a vacuum seal1830 can have a flexible layer 1834 on a compressible layer 1831. Thevacuum seal 1830 can be coupled to a base element 1811. Under acompressed force on the vacuum gripper, the compressible layer 1831 canbe compressed 1831*, and the flexible layer 1834 can be flexed 1834* atirregular surface area.

FIGS. 18B(a)-18B(c) show a process for improving conformity of thevacuum seal with a step surface of an object. In FIG. 18B(a), a vacuumgripper, having a vacuum seal which includes a flexible layer 1834 on adeformable layer 1831, is placed on an object surface that contains astep 1862. When placed on the object, the vacuum seal can rests on thehigher portion of the step, with a gap with the lower portion. A force1840 is applied to the vacuum gripper, which is transferred to thevacuum seal. The vacuum seal can be deformed to meet the object surface.Far away from the step, the vacuum seal contacts the object surface. Atthe vicinity of the step, there can be a gap 1865 between the vacuumseal and the lower corner of the step, especially if the step is abrupt.

In FIG. 18B(b), a press rod 1864 is used to pressed on the flexiblelayer at location of the gap 1865, e.g., using a force 1864* on thepress rod. The deformable layer 1831 can be soft and easily deformed toconform to the irregularities of the object surface. Without theflexible layer 1834, pressing on the top side of the soft deformablelayer 1831 can form a localized dent at the pressed area, but withminimum effect at the opposite bottom side of the deformable layer 1831.The flexible layer 1834 is formed from a harder material than thedeformable layer 1831, thus, pressing on the flexible layer can form alarger dent, which can cause the deformable layer 1831 to move at thebottom side surface to fill the gap 1865.

In some embodiments, the flexible layer is chosen, e.g., layerthickness, layer hardness, or layer flexibility, to assist in making thedeformable layer more conforming to the irregularities of the objectsurface, such as to fill in the gap 1865 at a step surface. For example,the flexible layer and the deformable layer are chosen to allow a force1864* from a press rod 1864 on the flexible layer to cause thedeformable layer to protrude at the opposite surface. The flexible layercan be configured to be deformed with a less localized pattern than thedeformable layer under a point indentation. Alternatively oradditionally, the flexible layer can be configured to generate at leasta protruded portion in an opposite surface of the deformable layer underthe point indentation. The press rod can be pushed at an angle from thevertical direction, such as at a direction pointing toward the gap.

As a result, pushing on a press rod 1864 at the gap area can helpreducing the size of the gap 1865 to provide adequate vacuum suctionforce between the vacuum gripper and the object (FIG. 18B(c)).

FIGS. 18C(a)-18C(c) show a process for improving conformity of thevacuum seal with a groove surface of an object. In FIG. 18C(a), thevacuum gripper is placed on an object surface that contains a groove1863. When placed on the object, the vacuum seal can rests on the flatportion of the surface, with a gap with the groove. A force 1840 isapplied to the vacuum gripper, which is transferred to the vacuum seal.The vacuum seal can be deformed to meet the object surface. For shallowand gradually transition groove, the vacuum seal can be conformal to thegroove surface. For deep groove or for abrupt groove, there can be a gap1865 between the vacuum seal and the lower portion of the groove,especially at the bottom corners of the groove.

In FIG. 18C(b), a press rod 1864 is used to pressed on the flexiblelayer at locations of the gap 1865, e.g., using a force 1864* on thepress rod. The pressing force 1864* can form a larger dent, which cancause the deformable layer 1831 to move at the bottom side surface tofill the gap 1865. The press rod can be pushed at a straight directionpointing toward the gap.

As a result, pushing on a press rod 1864 at the gap area can helpreducing the size of the gap 1865 to provide adequate vacuum suctionforce between the vacuum gripper and the object (FIG. 18C(c)).

Support for Top Flexible Layer

In some embodiments, the flexible layer can be configured to just coverthe periphery of the vacuum gripper, e.g., running along the vacuum sealportion of the vacuum gripper. Alternatively, the flexible layer canalso cover the whole surface of the cavity, e.g., covering the bottomside of the base element. The flexible layer can have a flexible supportat the middle portion of the flexible layer, for example, to providerigidity and also flexibility for the vacuum gripper when coupling toirregular object surface.

FIGS. 19A-19C illustrate a configuration for a flexible support for aflexible layer according to some embodiments. In FIG. 19A, a vacuum seal1930 can have a flexible layer 1934 on a compressible layer 1931. Thevacuum seal 1930 can be coupled to a base element 1911 around aperiphery of the base element. The flexible layer can also cover thebase element, e.g., on top of the peripheral vacuum seal and also at themiddle portion of the base element. Thus, the cavity can be formedbetween the vacuum seal and the flexible layer, together with the objectsurface.

The flexible layer 1934 can include a flexible support 1967, disposedinside the area surrounded by the compressible layer 1931. The flexiblesupport 1967 is configured to be rigid enough to provide strength to thevacuum gripper, and flexible enough to accommodate the bending of thecompressible layer when encountering an irregular object surface.

FIG. 19B shows a cross section view of the flexible support across thecompressible layer, together with surrounding components. The flexiblelayer and the compressible layer can bend when encountering a stepobject surface. Under the action of a press rod 1964, the bottom surfaceof the compressible layer 1931 is pressed down to contact the stepsurface.

FIG. 19C shows a cross section view of the flexible support across aportion of the flexible support, together with surrounding components.The flexible support is flexible enough to allow the compressible layer1931 and the flexible layer 1934 to bend in response to the step objectsurface. Under the action of a press rod 1964, the bottom surface of thecompressible layer 1931 is pressed down to contact the step surface.

Formation and Operation of the Flexible Support

FIGS. 20A-20B illustrate a formation and operation of a flexible supportaccording to some embodiments. In FIG. 20A, operation 2000 forms avacuum gripper for gripping an object surface. The vacuum gripperincludes a base element, a close-loop vacuum seal element coupled to asurface of the base element to form a sealed cavity when contacting theobject surface, a vacuum pump coupled to the base element and fluidlycommunicated with the cavity for evacuating air in the cavity.

The vacuum seal element includes a compressible material, a multiplayercompressible material, a composite gradually varied compressiblematerial, or a compressible structure having a pneumatic or hydraulicelement having a flexible layer surrounding a fluid filled cavity. Thevacuum gripper further includes a flexible layer disposed between thebase element and the vacuum seal element. The flexible layer isconfigured to deform in a same surface with a less localized patternthan the compressible material under a point indentation. The flexiblelayer is configured to deform more in an opposite surface than thecompressible material under the point indentation, by having higherhardness. The flexible layer includes a flexible support in area insidethe close-loop vacuum seal element. The vacuum gripper optionallyincludes a press rod for pressing on the flexible layer to assist thecompressible layer to be conformed to irregularities of the objectsurface.

In FIG. 20B, operation 2020 generates a vacuum in a cavity of a vacuumgripper after coupling the vacuum gripper to a panel surface. Operation2030 presses on selective areas of a vacuum seal element of the vacuumgripper to conform the vacuum seal element at irregular surfacelocations of the panel surface.

Vacuum Gripper with Openings in Base Element

In some embodiments, the present invention discloses a vacuum gripperhaving openings in a base element, e.g., in a body of the vacuum gripperto expose the vacuum seal. There can be one opening along a periphery ofthe base element. Alternatively, there can be multiple openingsseparated by connecting ridges between an outer periphery and a middleportion of the base element.

In some embodiments, a vacuum gripper can be formed for gripping anobject surface. The vacuum gripper includes a base element havingopenings around a periphery. The base element can be a plate, which canserve as a body for the vacuum gripper. A handle can be coupled to thebase element, such as a top side facing an operator.

The vacuum gripper includes a flexible layer having a flexible portionand a compressible portion. The flexible portion is disposed along theperiphery to be accessible through the openings in the base element. Thecompressible portion is served as a support and formed in a middle ofthe flexible portion. The compressible is coupled to the base element.

The compressible portion includes a more compressible material than theflexible portion. The compressible portion is located outside aperiphery of the vacuum seal element, or located in an inner areaportion of the base element.

In some embodiments, the flexible layer is configured to be deformedwith a less localized pattern than the elastic deformable material undera point indentation. Alternatively or additionally, the flexible layeris configured to be protruded more in an opposite surface than theelastic deformable material under the point indentation. Alternativelyor additionally, the flexible layer comprises a higher hardness than theelastic deformable material.

The vacuum gripper includes a vacuum seal element coupled to theflexible layer. The vacuum seal element can include an elasticdeformable material with the deformable characteristic used to provideconformity with irregular object surfaces, such as rough surfaces, orsurfaces with grooves or steps. The deformable seal element can bestretched and compressed to follow the variations of the object surface,so that an adequate vacuum level can be formed within the cavity.

The vacuum seal element and the flexible layer are configured to form acavity with the object surface contacted by the vacuum gripper. Theopenings in the base element are configured to allow the flexible layerto be pressed toward the vacuum seal element to assist the vacuum sealelement to be conformed to irregularities of the object surface.

The vacuum seal element can be coupled to the flexible layer along theperiphery. Alternatively, the vacuum seal element is coupled to theflexible layer at an inner portion inside a periphery of the vacuum sealelement, with the inner portion comprising a thickness less than theperipheral portion.

In some embodiments, the elastic deformable material includes multipledifferent elastic deformable materials, with the multiple differentelastic deformable materials arranged in discrete layers, or forming acomposite layer having continuously varying levels of elasticdeformation. The multiple different elastic deformable materials areconfigured to balance contact forces on the vacuum seal element whenencounter the object surface that comprises a surface roughness.

In some embodiments, the elastic deformable material includes apneumatic or hydraulic element comprising a flexible and stretchablelayer forming a fluid-filled cavity, with the fluid-filled cavity has apressure optimized for sealing the vacuum seal element on the objectsurface when the object surface is non-smooth.

In some embodiments, the vacuum gripper further has a press rod,configured to be removably coupled to the base element. A size of thepress rod is smaller than an opening of the openings to be used forpressing on the flexible layer through the opening.

The vacuum gripper includes an air extraction mechanism coupled to thebase element and in fluid communication with the cavity. The airextraction mechanism is configured to extract gas from the cavity tocreate a suction force for coupling the object surface to the vacuumgripper. The air extraction mechanism can include a motor configured topump air out of the cavity, such as a motorized air pump. The airextraction mechanism can include other system configured to remove airfrom the cavity, such as an impeller, or a high flow Venturiconstruction. The air extraction mechanism can be housed in a handle,e.g., a hollow handle can be coupled to the base element, with the airextraction mechanism disposed within the hollow portion of the handle.

The vacuum gripper can include a second flexible layer coupled to thevacuum seal element, with the flexible layer having a material moredurable or more abrasion-resistant than that of the vacuum seal element.

The vacuum gripper can include hookable elements coupled to the baseelement, with the hookable elements configured to be coupled to a hoistmechanism.

The vacuum gripper can include a manual air extraction mechanism coupledto the second surface of the base element and in fluid communicationwith the cavity, with the manual air extraction mechanism configured toextract gas from the cavity to create a suction force for coupling theobject surface to the vacuum gripper. The manual air extractionmechanism is configured to be operated by a person.

The vacuum gripper can include a pressure gauge coupled to the baseelement and in fluid communication with the cavity, with the pressuregauge configured to provide indication of a pressure or vacuum level inthe cavity.

The vacuum gripper can include an air release mechanism coupled to thebase element and in fluid communication with the cavity, with the airrelease mechanism configured to release gas from the cavity.

The vacuum gripper can include a power source configured to providepower to the air extraction mechanism, with the power source housed in ahandle coupled to the second surface of the base element. The powersource can be a battery, such as a rechargeable battery. The powersource can be housed in the handle that houses the motorized pump. Forexample, the handle can have a C shape, with a middle portion parallelto the base element and coupled to two bars perpendicular to the baseelement at two end of the middle portion. The middle portion and the twoend bars are hollow to house the air extraction mechanism, such as anend bar is configured to house the motorized pump and the middle portionis configured to house the battery. The battery can be a rechargeablebattery, with a connector configured to accept a charger, such as aportable charger for charging the battery on the field, e.g., withoutrequiring an outlet.

The vacuum gripper can include a charging mechanism configured to chargethe power source, with the charging mechanism configured to charge thepower source from an external power supply or manually from a person.

The vacuum gripper can include a vacuum alarm, with the alarm configuredto provide an alarm when the pressure level in the cavity is above adetermined value.

The vacuum gripper can include a manual mechanism configured to maintainan operation of the vacuum gripper, with the manual mechanism configuredto extract gas from the cavity to lower the pressure level by a personwhen the alarm showing the pressure level is above the predeterminedvalue.

The vacuum gripper can include a battery alarm coupled to the powersource, with the battery alarm configured to provide an alarm to notifya person when a power level of the battery is below a determined value.

The vacuum gripper includes an alarm, configured to provide an alarmwhen a power level of the battery is below a predetermined battery valueor when the pressure level in the cavity is above a predeterminedpressure value. The alarm can alert an operator to care for the vacuumgripper, especially when the vacuum gripper is in use, e.g., holding andlifting or transporting an object.

The vacuum gripper includes a manual mechanism configured to maintain anoperation of the vacuum gripper, e.g., to address the cause of the alarmto clear the alarm to maintain the operation of the vacuum gripper. Inthe case of low battery alarm, the manual mechanism can include a remoteportable power source, or an integrated power generator for charging thebattery. For example, the manual mechanism can be configured to chargethe power source from an external power supply by an operator using aportable power source to connect to the battery for charging thebattery. The manual mechanism can be configured to manually charging thebattery by an operator using a manual charger mechanism such as a manualpower generator.

In the case of low vacuum alarm, e.g., high pressure in the cavity ofthe vacuum gripper, the manual mechanism can include an integratedmanual pump configured to extract gas from the cavity to lower thepressure level by an operator using a manual pump to pump air from thecavity.

The vacuum gripper includes a controller configured to regulate the airextraction mechanism. The power regulation can be configured to saveenergy, e.g., to prolong the vacuum generation in the cavity so that thevacuum gripper can hold and transport a load for longer time. In anintermittent power regulation, the controller is configured to turn offthe air extraction mechanism when a pressure level in the cavity reachesa predetermined pressure level or when a rate of pressure reduction inthe cavity reaches a predetermined level. The controller is alsoconfigured to turn on the air extraction mechanism when a pressure levelin the cavity is below the predetermined pressure level. Alternatively,the power regulation can use a variable power motor for the motorizedpump, e.g., the motorized pump can run at different power levels, suchas a full power for a maximum air extraction, or a lower power for lowerair extraction capability. The controller can run the variable motorbased on the cavity pressure, such as higher power when the cavitypressure or the rate of pressure change is high, and lower power whenthe cavity pressure or the rate of pressure change is low. When thepressure reaches steady state, e.g., when the rate of pressure change issmall, the controller can run the motor at a base power, which is enoughto compensate for the pressure loss to maintain the proper vacuum levelin the cavity.

FIGS. 21A-21C illustrate a configuration of a vacuum gripper having baseopenings according to some embodiments. FIG. 21A shows a perspectiveview of the portable vacuum gripper 2100 viewed from above, showing abody or base element 2111 of the gripper having openings 2168 disposedaround a periphery of the base element. The openings 2168 can be spacedfrom the edges of the base element, and are configured to expose aflexible layer 2134 on a compressible layer 2131 of a vacuum seal. Apressure gauge 2123 can be mounted on the base element for monitoringthe pressure or vacuum level in a gripping cavity of the vacuum gripper.The vacuum gripper has a handle 2110 disposed in a middle portion of thebase element. The handle is configured to house multiple components ofthe vacuum gripper, such as a motorized pump 2120, a manual pump, abattery pack, a manual vacuum release button, a power switch 2120A forturning on or off the motorized pump, hookable elements for couplingwith lifting cables, and a controller for regulating the motorized pumpto conserve power. The handle can have a recess for storing a press rod2164, which can be used for pressing on the flexible layer through theopenings for reducing potential gaps between the vacuum seal and theobject surface.

FIGS. 21B(a)-21B(c) show a cross section view across the compressiblelayer of a process for improving conformity of the vacuum seal with astep surface of an object. FIGS. 21C(a)-21C(c) show a cross section viewcutting through the compressible layer of a process for improvingconformity of the vacuum seal with a step surface of an object. The baseelement can remain rigid, while the flexible layer and the compressiblelayer can bend when encountering a step object surface. Under the actionof a press rod 2164, the bottom surface of the compressible layer 2131is pressed down to contact the step surface.

In FIG. 21B(a) and FIG. 21C(a), a vacuum gripper, having a vacuum sealwhich includes a flexible layer 2134 on a deformable layer 2131, isplaced on an object surface that contains a step 2162. When placed onthe object, the vacuum seal can rests on the higher portion of the step,with a gap with the lower portion.

In FIG. 21B(b) and FIG. 21C(b), the vacuum gripper is pressed down tomake contact with the object surface. The vacuum seal can be deformed tomeet the object surface. Far away from the step, the vacuum sealcontacts the object surface. At the vicinity of the step, there can be agap 2165 between the vacuum seal and the lower corner of the step.

A press rod 2164 is used to pressed on the flexible layer through anopening of the multiple openings, at the location of the gap 2165, e.g.,using a force 2164* on the press rod. The deformable layer 2131 moves atthe bottom side surface to fill the gap 2165.

As a result, pushing on a press rod 2164 at the gap area can helpreducing the size of the gap 2165 to provide adequate vacuum suctionforce between the vacuum gripper and the object (FIG. 21B(c) and FIG.21C(c)).

FIG. 22 illustrates a flow chart for forming a vacuum gripper withopenings according to some embodiments. Operation 2200 forms a vacuumgripper for gripping an object surface. The vacuum gripper includes abase element, a flexible layer at least partially coupled to a surfaceof the base element, a close-loop vacuum seal element at least partiallycoupled to the flexible layer, with the vacuum seal element configuredto form a sealed cavity with at least one of the base element or theflexible layer when contacting the object surface, and a vacuum pumpcoupled to the base element and fluidly communicated with the cavity forevacuating air in the cavity.

The vacuum seal element includes a compressible material, a multiplayercompressible material, a composite gradually varied compressiblematerial, or a compressible structure having a pneumatic or hydraulicelement having a flexible layer surrounding a fluid filled cavity.

The flexible layer is less compressible than the compressible vacuumseal element. The flexible layer is configured to deform in a samesurface with a less localized pattern than the compressible materialunder a point indentation. The flexible layer is configured to deformmore in an opposite surface than the compressible material under thepoint indentation, by having higher hardness. The flexible layerincludes a support in area inside or outside the close-loop vacuum sealelement. The support includes a flexible material or a compressiblematerial.

The base element includes openings around a periphery at locations ofthe vacuum seal element for a press rod to press on the flexible layeror on the vacuum seal element to assist the compressible layer to beconformed to irregularities of the object surface.

FIG. 23 illustrates a process for operating a vacuum gripper withopenings according to some embodiments. Operation 2300 couples a vacuumgripper to a panel surface. Operation 2310 turns on a motor forgenerating a vacuum in a cavity of the vacuum gripper. Operation 2320presses on the vacuum gripper to assist the vacuum seal element inconforming to surface irregularities of the panel surface. Operation2330 presses on selective areas of a vacuum seal element of the vacuumgripper, using a press rod, to further conform the vacuum seal elementat the surface irregularities. Operation 2340 continues presses on thevacuum gripper and on the vacuum seal until reaching a vacuum orpressure level. Operation 2350 automatically turns off the motor whenthe vacuum or pressure level is reached. Operation 2360 automaticallyturns on the motor when the vacuum in the cavity drops below the vacuumor pressure level. Operation 2370 automatically turns on a chargingsystem for charging a battery of the vacuum gripper when a battery levelis below a predetermined battery level.

Configurations of Vacuum Grippers with Openings

In some embodiments, the vacuum gripper can have a flexiblelayer/compressible layer seal coupled to a rigid base element. The baseelement can be rigid for support the handle and other components. Theflexible layer and the compressible layer seal can be flexible anddeformable to match with the irregularities of the object surface. Thecoupling of the flexible layer to the base element can include anotherdeformable layer to allow for the movements of the flexible layer whilethe base element remains rigid.

FIGS. 24A-24E illustrate configurations for the coupling between a baseelement and a flexible layer according to some embodiments. In FIG. 24A,the compressible layer 2431 of the vacuum seal has a close loop shaperunning around a periphery of the base element 2411. The flexible layer2434 is coupled to the compressible layer 2431 along the periphery. Theflexible layer 2434 has a flexible support 2467 above and below theflexible layer, with the flexible support disposed at an area inside theperiphery. The top portion of the flexible support, e.g., the portion ofthe flexible support above the flexible layer is coupled to the baseelement 2411. The flexible support can include an elastic deformablematerial, such as being compressible and stretchable. The deformablecharacteristic of the flexible support can allow the vacuum seal to bendto match the irregularities of the object surface, while keeping thebase element rigid.

In FIG. 24B, the compressible layer 2431 of the vacuum seal has a closeloop shape running around a periphery of the base element 2411. Theflexible layer 2434 is coupled to the compressible layer 2431 along theperiphery. The flexible layer 2434 has a flexible support 2467 above theflexible layer, with the flexible support disposed at most areas, e.g.,in areas along the periphery and in areas inside the periphery. The topportion of the flexible support, e.g., the portion of the flexiblesupport above the flexible layer is coupled to the base element 2411.The openings of the base element also see the flexible support, thus thepress rod can press on the flexible support to push on the flexiblelayer to affect the compressible layer.

In FIG. 24C, the compressible layer 2431 of the vacuum seal has a closeloop shape running around a periphery of the base element 2411. Theflexible layer 2434 is coupled to the compressible layer 2431 along theperiphery. The flexible layer 2434 has a flexible support 2467 above andbelow the flexible layer, with the flexible support disposed at an areainside the periphery. The top portion of the flexible support, e.g., theportion of the flexible support above the flexible layer, includes ahydraulic or pneumatic element having a silicone or rubber 2467A outerlayer containing a cavity filled with a fluid, such as air 2467B. Thepressure in the cavity of the pneumatic or hydraulic element can beadjustable, to be optimized for the conformity of the base element withthe vacuum seal element.

In FIG. 24D, the compressible layer 2431 of the vacuum seal has a closeloop shape running around a periphery of the base element 2411, togetherwith a thinner layer at the portion within the peripheral portion. Theflexible layer 2434 is coupled to the compressible layer 2431 along theperiphery and also at the inside portion. The flexible layer 2434 has aflexible support 2467 above the flexible layer, with the flexiblesupport disposed at an area inside the periphery and also outside theperiphery. The top portion of the flexible support is coupled to thebase element 2411, e.g., at areas outside and inside the periphery ofthe base element.

In FIG. 24E, the compressible layer 2431 of the vacuum seal has a closeloop shape running around a periphery of the base element 2411. Theflexible layer 2434 is coupled to the compressible layer 2431 along theperiphery. The flexible layer 2434 has a flexible support 2467 above andbelow the flexible layer, with the flexible support disposed at an areainside the periphery and also outside the periphery. The top portion ofthe flexible support is coupled to the base element 2411, e.g., at areasoutside and inside the periphery of the base element. The top portion ofthe support has an opening around the periphery of the base element, toexpose the flexible layer.

FIG. 25 illustrates a process for forming a vacuum gripper according tosome embodiments. Operation 2500 forms a vacuum gripper for gripping anobject surface. The vacuum gripper includes a base element, a flexiblelayer having a compressible portion coupled to a surface of the baseelement, a close-loop vacuum seal element coupled to the flexible layer,with the vacuum seal element configured to form a sealed cavity with atleast one of the base element or the flexible layer when contacting theobject surface, and a vacuum pump coupled to the base element andfluidly communicated with the cavity for evacuating air in the cavity.

The vacuum seal element includes a compressible material, a multiplayercompressible material, a composite gradually varied compressiblematerial, or a compressible structure having a pneumatic or hydraulicelement having a flexible layer surrounding a fluid filled cavity.

The base element includes at least an opening at a periphery of thevacuum seal element for a press rod to press on the flexible layer or onthe vacuum seal element to assist the compressible layer to be conformedto irregularities of the object surface.

The compressible portion of the flexible layer is at a middle portion ofthe flexible layer inside the periphery of the vacuum seal element. Thecompressible portion of the flexible layer is optionally at a portion ofthe flexible layer outside the periphery of the vacuum seal element. Thevacuum seal element optionally includes a flexible portion inside theperiphery of the vacuum seal element, with the flexible portion having athickness less than the peripheral portion.

Deformation Characteristics of the Vacuum Seal with Local Pressing

In some embodiments, the vacuum seal element is configured to form aclose seal with an irregular surface of an object with the use of apress rod pressing on localized areas of the vacuum seal. For example,facing a sharp and deep corner of the object surface, the vacuum sealmight still leave a gap, even with a high force pressing on the vacuumgripper, since the high force pressing is global with most of thepressing force distributed to other contact areas. A local force, suchas a force provided by a press rod pressing on the vacuum seal area atthe gap location, can push the vacuum seal into the gap for reducing thegap size and forming adequate suction force between the gripper and theobject.

In some embodiments, the vacuum seal is configured to allow a materialtransfer from a top surface to a bottom surface of the vacuum seal, sothat a pressing on the top surface can cause the bottom surface to bedeformed, such as protruding to fill the gap. Thus, in addition to be ahighly compressible material to conform to the variation of the objectsurface, the vacuum seal also includes a high hardness material to allowmovements of bottom layer when the top layer is pushed. Thus, the vacuumseal can include a composite material, such as having a highlycompressible at a bottom side and a less compressible or higher hardnessat a top side.

FIGS. 26A-26H illustrate configurations of a vacuum seal according tosome embodiments. In FIG. 26A, a soft compressible seal 2631 can bedeformed upon being pressed on an irregular surface, such as a surfacewith a bump. The bottom side of the seal can form depression 2671Amatching with the bump of the surface. There can be minimum changes atthe opposite side, e.g., at the top side, of the seal. Similarly, softcompressible seal can be deformed to form a dimple 2670B having adepression 2671B when being pressed at a top surface, for example, by apress rod. There also can be minimum changes at the opposite side, e.g.,at the bottom side, of the seal.

In contrast, for a harder material such as a flexible layer 2634, bothtop and bottom sides of the flexible layer are deformed with similarshapes when being pressed with a press rod, for example, forming adimple 2670B.

FIG. 26B shows a configuration of a composite seal having a flexiblelayer 2634 disposed on a compressible layer 2631. The hardness andthickness of each layer can be optimized to allow conformity with theobject surface, while allow a bottom portion of the seal to protrudedupon being pressed at a top portion. A force 2664* by a press rod can beapplied to the flexible layer. The force can cause a dimple 2670B* onthe flexible layer with a depression 2671B*. The compressible layer isdeformed at a bottom side by the dimple 2670B* and depression 2671B*, togenerate a dimple 2670C and depression 2671C. The flexible layer and thecompressible layer are chosen to provide the dimple 2670C and depression2671C suitable for filling gaps caused by the irregularities of theobject surface.

FIG. 26C shows a configuration of a composite seal having a lesscompressible 2634A disposed on a more compressible layer 2631B. Thehardness and thickness of each layer can be optimized to allowconformity with the object surface, while allow a bottom portion of theseal to protruded upon being pressed at a top portion. For example, themore compressible layer 2631B can be a soft compressible, e.g., highlycompressible, while the less compressible layer 2631A can be a hardcompressible, e.g., mediumly compressible.

FIG. 26D shows a configuration of a composite seal having a flexiblelayer disposed on a less compressible 2634A disposed on a morecompressible layer 2631B. The hardness and thickness of each layer canbe optimized to allow conformity with the object surface, while allow abottom portion of the seal to protruded upon being pressed at a topportion.

FIG. 26E shows a configuration of a composite seal having a graduallycompressible material 2672. The hardness and thickness curve of thecomposite seal can be optimized to allow conformity with the objectsurface, while allow a bottom portion of the seal to protruded uponbeing pressed at a top portion.

FIG. 26F shows a configuration of a composite seal having a flexiblelayer disposed on a gradually compressible material 2672. The hardnessand thickness of each layer can be optimized to allow conformity withthe object surface, while allow a bottom portion of the seal toprotruded upon being pressed at a top portion.

FIG. 26G shows a configuration of a composite seal having a hydraulic orpneumatic tube, such as rubber 2632A, filled with a fluid, such as air2632B. The rubber layer can function as the hard flexible layer, whilethe air can function as the soft compressible layer. The air pressurecan be optimized to allow conformity with the object surface, whileallow a bottom portion of the seal to protruded upon being pressed at atop portion.

FIG. 26H shows a configuration of a composite seal having a flexiblelayer disposed on a hydraulic or pneumatic tube filled with a fluid.Alternatively, the hydraulic or pneumatic tube can have a thicker layeron top, which can function as a flexible layer.

FIGS. 27A-27I illustrate configurations for a vacuum seal according tosome embodiments. FIG. 27A shows a flexible thin layer 2734 disposed ona rubber tube seal having pressured air 2732B inside a rubber wall2732A, with the rubber tube seal disposed on a bottom flexible layer2761. FIG. 27B shows a flexible thin layer 2734 disposed on a sealhaving layers 2736, 2735, and 2731, each with different compressible andstretchable material, with the seal disposed on a bottom flexible layer2761. FIG. 27C shows a flexible thin layer 2734 disposed on a sealhaving a layer 2731, with the seal disposed on a bottom flexible layer2761. FIG. 27D shows a flexible thin layer 2734 disposed on a sealhaving layers 2735/2731 on a rubber tube seal 2732A/2732B. FIG. 27Eshows a flexible thin layer 2734 disposed on a seal having a layer 2731on a rubber tube seal 2732A/2732B. FIG. 27F shows a flexible thin layer2734 disposed on a seal having a rubber tube 2732A1 on a rubber tubeseal 2732A. FIG. 27G shows a flexible thin layer 2734 disposed on a sealhaving a rubber tube 2732A which is disposed on a seal having layers2735/2731. FIG. 27H shows a flexible thin layer 2734 disposed on a sealhaving a rubber tube 2732A, which is disposed on another flexible layer2734A, which is disposed on a seal having layers 2735/2731. FIG. 27Ishows a flexible thin layer 2734 disposed on two seals having rubbertubes 2732A1 and 2732A, with another flexible thin layer 2734A betweenthe two rubber tubes.

FIG. 28 illustrates a process to form a vacuum gripper according to someembodiments. Operation 2800 forms a vacuum gripper for gripping anobject surface. The vacuum gripper includes a base element, a flexiblelayer having a compressible portion coupled to a surface of the baseelement, a close-loop vacuum seal element coupled to the flexible layer,with the vacuum seal element configured to form a sealed cavity with atleast one of the base element or the flexible layer when contacting theobject surface, and a vacuum pump coupled to the base element andfluidly communicated with the cavity for evacuating air in the cavity.

The vacuum seal element includes a compressible material having agradual varying compressible property. The vacuum seal element includesa compressible material having multiple layers of different compressibleproperties. The vacuum seal element includes a compressible structurehaving a pneumatic or hydraulic element having a flexible layersurrounding a fluid filled cavity. The vacuum seal element includes acompressible material on a flexible layer. The vacuum seal elementincludes a compressible material having a combination of two or morelayers of a gradual varying compressible property, multiple layers ofdifferent compressible properties, a pneumatic or hydraulic elementhaving a second flexible layer forming a fluid filled cavity, or a thirdflexible layer.

The layers of the vacuum seal element are optimized for a sealing of thevacuum seal element on a height variation object surface.

The flexible layer is less compressible than the compressible vacuumseal element. The flexible layer is configured to deform in a samesurface with a less localized pattern than the compressible materialunder a point indentation. The flexible layer is configured to deformmore in an opposite surface than the compressible material under thepoint indentation, by having higher hardness.

Vacuum Gripper with a Pin Array

In some embodiments, a portable vacuum gripper can include componentsfor selectively deforming the vacuum seal according to the underlyingsurface. For example, the components can include pins disposed along aperiphery of the portable vacuum gripper on the vacuum seal. By pressingthe pins according to the pattern of the sealing surface, the vacuumseal can be appropriately deformed to form a seal with the objectsurface.

For example, a portable vacuum gripper can be used for lifting an objecthaving a grooved surface. The portable vacuum gripper can be placed onthe grooved surface, and pins at the groove areas can be pushed down topush the vacuum seal further down on the grooves for making a betterseal with the grooved surface.

In some embodiments, a vacuum gripper includes a base element, an arrayof press rods coupled to a periphery of the base element, a flexiblelayer comprising a flexible portion and a compressible portion, with theflexible portion disposed along the periphery to be accessible throughthe openings, and the compressible portion coupled to the base element,a vacuum seal element coupled to the flexible layer, with the vacuumseal element including an elastic deformable material.

The press rods are configured to be movable toward the vacuum sealelement by sliding, by rotating, by screwing, or by pressing down. Thepress rods are configured to be pressed on the flexible layer toward thevacuum seal element to assist the vacuum seal element to be conformed toirregularities of the object surface.

The vacuum gripper also includes an air extraction mechanism coupled tothe second surface of the base element and in fluid communication withthe cavity, with the air extraction mechanism configured to extract gasfrom the cavity to create a suction force for coupling the objectsurface to the vacuum gripper.

The vacuum gripper can also include other components, such as a handlecoupled to the second surface of the base element, a power sourceconfigured to provide power to the air extraction mechanism, acontroller configured to regulate the air extraction mechanism, analarm, and a manual mechanism configured to maintain an operation of thevacuum gripper, with the charging mechanism configured to charge thepower source from an external power supply or manually from a personwhen the alarm showing the power level is below the first predeterminedvalue, or to extract gas from the cavity to lower the pressure level bya person when the alarm showing the pressure level is above the secondpredetermined value.

FIGS. 29A-29B illustrate a portable vacuum gripper having seal deformingcomponents according to some embodiments. In FIG. 29A, a portable vacuumgripper 2900 can include a body 2911*, which can include a base element2911 and a handle 2910. The handle 2910 can be designed to house amotorized pump 2920, a manual pump 2921, a battery pack disposed in thehandle, a power button 2925 for turning on the motorized pump, and amanual vacuum release button 2912. The base element 2911 can be designedto house a pressure gauge 2923 (or a vacuum gauge), which can providethe level of pressure or vacuum in a cavity of the portable vacuumgripper. Hookable elements 2926 can be formed on the base element forattaching to hooks for hoisting.

The portable vacuum gripper 2900 can be configured to have multiple sealdeforming components, such as movable pins 2942, disposed on a topsurface of the vacuum seal. The pins 2942 can move down, for example, byan operator pushing down on the pins. The movement of the pins can causethe vacuum seal to be deformed, such as to be pushed down. Thus, thepins corresponded to a groove or a step on a surface can be pushed down,which can assist in deforming the vacuum seal into the shape of theunderlying surface to form a better seal.

In FIG. 29B(a), the portable vacuum gripper 2900 can include a vacuumseal 2931 disposed under a flexible layer 2934. The portable vacuumgripper 2900 can include an array of pins disposed along a length of thevacuum seal 2931. In FIG. 29B(b), the portable vacuum gripper 2900 canbe placed on an irregular surface, such as on a step surface. The vacuumseal 2931 can be somewhat deformed to seal with the step surface. Inaddition, pins 2942A of the pin array 2942 can be pushed down, which canassist in the deformation of the vacuum seal, and which can make abetter seal with the step surface.

FIGS. 30A-30D illustrate configurations for seal deforming componentsaccording to some embodiments. In FIG. 30A, a pressurized pocket 3041inside a housing 3011 can be disposed on a flexible layer 3034 which isdisposed on a vacuum seal 3031. The pressurized pocket 3041 can beconfigured to accept a gas flow for regulating the pressure inside thepressurized pocket. The force exerted by the pressurized pocket can beuniform along the length of the vacuum seal on a flat surface. On a stepsurface, the force can push the vacuum seal further down at lower stepareas, which can assist in the deformation of the vacuum seal.

In FIG. 30B, multiple pins 3042 can be arranged on a support 3043 whichruns along the length of the vacuum seal. The pins can be uniformlydistributed along the length of the vacuum seal. The pins 3042 can bepushed down, relative to the support 3043. On a step surface, the pinscorresponded to the lower step areas can be pushed down, which can pushthe vacuum seal further down at lower step areas, which can assist inthe deformation of the vacuum seal.

In FIG. 30C, multiple pins 3044 can be arranged on a support which runsalong the length of the vacuum seal. The pins 3044 can be configured tomove along the support, e.g., the pins can be move along the support tobe positioned on a desired location, such as at the location of a grooveor a lower step area. The number of pins can be less than a uniformdistribution of pins, since the pins can be re-arranged to meet the stepdown areas. For example, the number of pins can be less than 20, lessthan 15, or less than 10 pins.

On a step surface, a pin can be slide along the support to be positionedat the lower step areas. The slide pin can then be pushed down, whichcan push the vacuum seal further down at lower step areas, which canassist in the deformation of the vacuum seal.

In FIG. 30D, multiple pins 3045 can be arranged on a support which runsalong the length of the vacuum seal. The pins 3045 can be configured tomove along the support, e.g., the pins can be move along the support tobe positioned on a desired location, such as at the location of a grooveor a lower step area. The pins 3045 can also be configured to rotatearound an axis, in order to position the pins in any direction, such asin a direction that can push the vacuum seal toward the step corner. Thesliding and rotating pins can be positioned to push at a step corner,which can assist in deforming the vacuum seal at the step corner for abetter seal.

FIGS. 31A-31C illustrate configurations for seal deforming componentsaccording to some embodiments. In FIG. 31A, a pressurized pocket 3141inside a housing 3111 can be disposed on a flexible layer 3134 which isdisposed on a vacuum seal 3131. The pressurized pocket 3141 can beconfigured to accept a gas flow for regulating the pressure inside thepressurized pocket. The force exerted by the pressurized pocket can beuniform along the length of the vacuum seal on a flat surface. On a stepsurface, the force can push the vacuum seal further down at lower stepareas, which can assist in the deformation of the vacuum seal.

In FIG. 31B, the pins can be screwed 3146 on a support, thus by rotatingthe pins, the pins can push down on the vacuum seal. In FIG. 31C, thepins can be pushed down 3147 on a support. The pins and the support canbe configured to keep the pins in the pushed down positions, forexample, by making a rough pins with a high friction support such aslining with a rubber material 3148. Thus, by pressing on the pins, thepins can stay down,

The support can have a release configuration, for example, by separatingthe support into two portions, leaving the pins free to move up, forexample, by a spring action. Thus, the release configuration can releaseall pins at once, while the pushing down action can be performed onindividual pins.

FIG. 32 illustrates a process for forming a vacuum gripper having a pinarray according to some embodiments. Operation 3200 forms a vacuumgripper for gripping an object surface. The vacuum gripper includes abase element, a flexible layer having a compressible portion coupled toa surface of the base element, a close-loop vacuum seal element coupledto the flexible layer, with the vacuum seal element configured to form asealed cavity with at least one of the base element or the flexiblelayer when contacting the object surface, and a vacuum pump coupled tothe base element and fluidly communicated with the cavity for evacuatingair in the cavity.

The vacuum seal element includes a compressible material having agradual varying compressible property, a compressible material havingmultiple layers of different compressible properties, a compressiblestructure having a pneumatic or hydraulic element having a flexiblelayer surrounding a fluid filled cavity, a compressible material on aflexible layer, or any combination thereof. The layers of the vacuumseal element are optimized for a sealing of the vacuum seal element on aheight variation object surface. The flexible layer is configured toimprove a conformation of the vacuum seal element on the object surfacewhen being pressed.

The vacuum gripper includes movable pins disposed around a periphery atlocations of the vacuum seal element for pressing on the flexible layeror on the vacuum seal element to assist the compressible layer to beconformed to irregularities of the object surface. The movable pins areconfigured to be movable toward the vacuum seal element by sliding, byrotating, by screwing, or by pressing down.

FIGS. 33A-33D illustrate flow charts for operating seal deformingcomponents in a portable vacuum gripper according to some embodiments.The seal deforming components can assist in selectively deforming thevacuum seal to be conformed to irregular surfaces, such as stepsurfaces, groove surfaces, or rough surfaces.

In FIG. 33A, operation 3300 pressurizes a deformable air pocket disposedalong a length of a seal to cause the seal to conform to an irregularsurface. In FIG. 33B, operation 3320 moves, toward an irregular surface,individual pins in an array of pins disposed along a length of a seal tocause the seal to conform to the irregular surface.

In FIG. 33C, operation 3340 slides or rotates individual pins in anarray of pins disposed along a length of a seal to cause the seal toconform to the irregular surface. In FIG. 33D, operation 3360 screws orpresses down individual pins in an array of pins disposed along a lengthof a seal to cause the seal to conform to the irregular surface.

What is claimed is:
 1. A vacuum gripper for gripping an object surface,the vacuum gripper comprising a base element, wherein the base elementcomprises openings around a periphery; a flexible layer comprising aflexible portion and a compressible portion, wherein the flexibleportion is disposed along the periphery to be accessible through theopenings, wherein the compressible portion is coupled to the baseelement; a vacuum seal element coupled to the flexible layer, whereinthe vacuum seal element comprises a deformable material, wherein thevacuum seal element and the flexible layer are configured to form acavity with the object surface contacted by the vacuum gripper, whereinthe openings are configured to be allow the flexible layer to be pressedtoward the vacuum seal element to assist the vacuum seal element to beconformed to irregularities of the object surface; an air extractionmechanism coupled to the second surface of the base element and in fluidcommunication with the cavity, wherein the air extraction mechanism isconfigured to extract gas from the cavity to create a suction force forcoupling the object surface to the vacuum gripper.
 2. A vacuum gripperas in claim 1, wherein the compressible portion comprises a morecompressible material than the flexible portion, wherein thecompressible portion is located outside the periphery.
 3. A vacuumgripper as in claim 1, wherein the compressible portion comprises a morecompressible material than the flexible portion, wherein thecompressible portion is located inside the periphery.
 4. A vacuumgripper as in claim 1, wherein the flexible layer is configured to bedeformed with a less localized pattern than the deformable materialunder a point indentation, or wherein the flexible layer is configuredto be protruded more in an opposite surface than the deformable materialunder the point indentation, or wherein the flexible layer comprises ahigher hardness than the deformable material.
 5. A vacuum gripper as inclaim 1, wherein the vacuum seal element is coupled to the flexiblelayer along the periphery.
 6. A vacuum gripper as in claim 1, whereinthe vacuum seal element comprises an inner portion inside the periphery,with the inner portion comprising a thickness less than that at aperipheral portion, wherein the vacuum seal element is coupled to theflexible layer at the inner portion.
 7. A vacuum gripper as in claim 1,wherein the deformable material comprises multiple different elasticdeformable materials, wherein the multiple different elastic deformablematerials are arranged in discrete layers.
 8. A vacuum gripper as inclaim 1, wherein the deformable material comprises multiple differentelastic deformable materials, wherein the multiple different elasticdeformable materials comprise a composite layer having continuouslyvarying levels of elastic deformation.
 9. A vacuum gripper as in claim1, wherein the deformable material comprises multiple different elasticdeformable materials, wherein the multiple different elastic deformablematerials are configured to balance contact forces on the vacuum sealelement when encounter the object surface that comprises a surfaceroughness.
 10. A vacuum gripper as in claim 1, wherein the deformablematerial comprises a pneumatic or hydraulic element comprising aflexible and stretchable layer forming a fluid-filled cavity, whereinthe fluid-filled cavity comprises a pressure optimized for sealing thevacuum seal element on the object surface when the object surface isnon-smooth.
 11. A vacuum gripper as in claim 1, further comprising asecond flexible layer coupled to the vacuum seal element at an oppositeside of the flexible layer, wherein the second flexible layer comprisesa material more durable or more abrasion-resistant than that of thevacuum seal element.
 12. A vacuum gripper as in claim 1, furthercomprising hookable elements coupled to the base element, wherein thehookable elements are configured to be coupled to a hoist mechanism. 13.A vacuum gripper as in claim 1, further comprising a manual airextraction mechanism coupled to the second surface of the base elementand in fluid communication with the cavity, wherein the manual airextraction mechanism is configured to extract gas from the cavity tocreate a suction force for coupling the object surface to the vacuumgripper, wherein the manual air extraction mechanism is configured to beoperated by a person; a pressure gauge coupled to the base element andin fluid communication with the cavity, wherein the pressure gauge isconfigured to provide indication of a pressure or vacuum level in thecavity; an air release mechanism coupled to the base element and influid communication with the cavity, wherein the air release mechanismis configured to release gas from the cavity.
 14. A vacuum gripper as inclaim 1, further comprising a power source configured to provide powerto the air extraction mechanism, wherein the power source is housed in ahandle coupled to the second surface of the base element; a batteryalarm coupled to the power source, wherein the battery alarm isconfigured to provide an alarm to notify a person when a power level ofthe battery is below a determined value; a charging mechanism configuredto charge the power source, wherein the charging mechanism is configuredto charge the power source from an external power supply or manuallyfrom a person.
 15. A vacuum gripper as in claim 1, further comprising analarm, wherein the alarm is configured to provide an alarm when thepressure level in the cavity is above a determined value; a manualmechanism configured to maintain an operation of the vacuum gripper,wherein the manual mechanism is configured to extract gas from thecavity to lower the pressure level by a person when the alarm showingthe pressure level is above the predetermined value.
 16. A vacuumgripper as in claim 1, further comprising a controller configured toregulate the air extraction mechanism, wherein the controller isconfigured to turn off the air extraction mechanism when a pressurelevel in the cavity reaches a predetermined pressure level or when arate of pressure reduction in the cavity reaches a predetermined level,wherein the controller is configured to turn on the air extractionmechanism when a pressure level in the cavity is below the predeterminedpressure level.
 17. A vacuum gripper as in claim 1, further comprising apress rod, wherein the press rod is configured to be removably coupledto the base element, wherein a size of the press rod is smaller than anopenings of the openings to be used for pressing on the flexible layerthrough the opening.
 18. A vacuum gripper for gripping an objectsurface, the vacuum gripper comprising a base element; an array of pressrods coupled to a periphery of the base element; a flexible layercomprising a flexible portion and a compressible portion, wherein theflexible portion is disposed along the periphery to be accessiblethrough the openings, wherein the compressible portion is coupled to thebase element; a vacuum seal element coupled to the flexible layer,wherein the vacuum seal element comprises a deformable material, whereinthe vacuum seal element and the flexible layer are configured to form acavity with the object surface contacted by the vacuum gripper, whereinthe press rods are configured to be movable toward the vacuum sealelement by sliding, by rotating, by screwing, or by pressing down,wherein the press rods are configured to be pressed on the flexiblelayer toward the vacuum seal element to assist the vacuum seal elementto be conformed to irregularities of the object surface; an airextraction mechanism coupled to the second surface of the base elementand in fluid communication with the cavity, wherein the air extractionmechanism is configured to extract gas from the cavity to create asuction force for coupling the object surface to the vacuum gripper. 19.A vacuum gripper as in claim 18, further comprising a handle coupled tothe second surface of the base element, wherein the handle is configuredto house the air extraction mechanism, a power source configured toprovide power to the air extraction mechanism, wherein the power sourceis housed in a handle coupled to the second surface of the base element;a controller configured to regulate the air extraction mechanism,wherein the controller is configured to turn off the air extractionmechanism when a pressure level in the cavity reaches a predeterminedpressure level or when a rate of pressure reduction in the cavityreaches a predetermined level, wherein the controller is configured toturn on the air extraction mechanism when a pressure level in the cavityis below the predetermined pressure level, an alarm, wherein the alarmis configured to provide an alarm when a power level of the battery isbelow a first determined value or when the pressure level in the cavityis above a second determined value; a manual mechanism configured tomaintain an operation of the vacuum gripper, wherein the chargingmechanism is configured to charge the power source from an externalpower supply or manually from a person when the alarm showing the powerlevel is below the first predetermined value, or to extract gas from thecavity to lower the pressure level by a person when the alarm showingthe pressure level is above the second predetermined value.
 20. A vacuumgripper for gripping an object surface, the vacuum gripper comprising abase element, a vacuum seal element coupled directly or indirectly tothe base element, wherein the vacuum seal element comprises an elasticdeformable material disposed around a periphery of the base element,wherein the vacuum seal element and the base element are configured toform a cavity with the object surface contacted by the vacuum gripper,an air extraction mechanism coupled to the second surface of the baseelement and in fluid communication with the cavity, wherein the airextraction mechanism is configured to extract gas from the cavity tocreate a suction force for coupling the object surface to the vacuumgripper, a power source configured to provide power to the airextraction mechanism, wherein the power source is housed in a handlecoupled to the second surface of the base element; a controllerconfigured to regulate the air extraction mechanism, wherein thecontroller is configured to turn off the air extraction mechanism when apressure level in the cavity reaches a predetermined pressure level orwhen a rate of pressure reduction in the cavity reaches a predeterminedlevel, wherein the controller is configured to turn on the airextraction mechanism when a pressure level in the cavity is below thepredetermined pressure level, an alarm, wherein the alarm is configuredto provide an alarm when a power level of the battery is below a firstpredetermined value or when the pressure level in the cavity is above asecond predetermined value; a manual mechanism configured to maintain anoperation of the vacuum gripper, wherein the manual mechanism isconfigured to charge the power source from an external power supply ormanually from a person when the alarm showing the power level is belowthe first predetermined value, or to extract gas from the cavity tolower the pressure level by a person when the alarm showing the pressurelevel is above the second predetermined value.